1371893623330-Steel and Aluminium Works PDF

Unified Standard Specifications For Works & Materials
Chapter 8 : Steel And Aluminium Works
Chapter 8
Steel And Aluminium Works
8.0. DEFINITIONS (Refer Figure 8.1 for
Details)
1.
Bead : A single run of weld metal
deposited on surface.
2.
Butt Weld : A weld in which the weld
metal lies substantially within the extension
of the planes and the surfaces of the parts
joined.
3.
Crater : A depression left in weld metal
where the arc was broken or the flame was
removed.
4.
End Crater : A crater at the end of a
weld or at the end of a joint.
5.
Fillet Weld : A weld of approximately
triangular cross-section joining two surfaces
approximately at right angles to each other in
a lap joint, tee joint or corner joint. It is of
two types :
(a) Continuous
(b) Intermittent
6.
Fusion Welding : Any welding process
in which the weld is made between metals in
a state of fusion without hammering or
pressure.
7.
Non-fusion Welding : A term applied to
the deposition, by the Oxy-Acetylene
process of filler metal on parent metal
without fusion of the latter.
8.
Oxy-Acetylene Pressure Welding :
Pressure welding in which any OxyAcetylene flame is used to make the surface
to be united plastic. No filler metal is used.
9.
Run : The metal deposited during one
passage of the electrode or blow pipe in the
making of a joint.
10. Throat thickness : See Figure 8.1
11. Weld : A union between two pieces of
metal at faces rendered plastic or liquid by
heat or pressure, or both. Filler metal maybe
used to effect the union.
8.1.
MATERIALS
8.1.1.
Steel
All finished steel shall be well and cleanly
rolled to the dimensions and weight specified
by BIS subject to permissible tolerances as
per IS:1852. The finished materials shall be
reasonably free from cracks, surface flaws,
laminations, rough and imperfect edges and
all other harmful defects.
Steel sections, shall be free from excessive

rust, scaling and pitting and shall be well
protected. The decision of the Engineer
regarding rejecting any steel section on
account of any of the above defects shall be
final and binding.
Structural steel work shall conform to the
following requirements. The mechanical and
chemical properties of the structural steel
shall be as per Annexure 8.1. The following
varieties of steel should be used for
structural purposes 8.1.1.1.
S.T. 42 S:
The standard
quality of steel designated as S.T. 42-S
conforming to IS : 226 shall be used for all
types of structures (riveted or bolted)
including those subject to dynamic loading
and where fatigue, wide fluctuation of
stresses and reversal of stresses are
involved, as for example crane gantry
girders, road and rail bridges etc., It is also
suitable for welded structures provided that
the thickness of materials does not exceed
20 mm.
8.1.1.2.
S.T. 42-W: The fusion welding
quality steel designated as S.T. 42-W
conforming to IS:2062 shall be used for all
types of structures subject to dynamic
loading (Wind load is not to be considered as
dynamic load for this purpose) where
welding is employed for fabrication and
where fatigue, wide fluctuation of stresses,
reversal of stress and great restraint are
involved as for example, crane gantry girders
and road and rail bridges.
8.1.1.3.
S.T. 42 0. The ordinary quality
steel designated as S.T. 42 0 conforming
to IS:1977 shall be used for structures not
subjected to dynamic loading other than wind
loads where welding is not employed or/and
structures not situated in earth quake zones
or design has not been based on plastic
theory.
8.1.1.4.
S.T. 32 0: The ordinary quality
steel designated as S.T. 32 0 conforming
to IS : 1977 shall be used for doors, window
frames, window bars, grills, steel gates, hand
railing, builders hardware, fencing posts, tie
bars etc.,
8.1.2.
Rivets
Rivets shall be made from rivet bars of mild
steel as per IS : 1148 and should conform to
the Indian Railways Standard Specifications.
Page 286 : Chapter 8
8.1.3.
Bolts
These are of two types namely turned &
fitted bolts and black bolts. Turned & fitted
bolts are turned to exact diameter in
automatic lathe. For these bolts, whether in
reamed or drilled holes, the same unit
stresses are allowed as for rivets. In case of
black bolts which are not finished to exact
sizes, a lower working stress other than for
turned bolts is adopted. They shall conform
to IS : 1367 (Technical supply conditions for
threaded steel fasteners) and relevant Indian
Railway Standard Specifications.
8.1.4
Using Rivets & Bolts : Rivets
or Turned and fitted bolts shall be used
where the connection such that slip under
load has to be avoided. Black bolts may be
used very sparingly where the force is
carried through the connection without
impact vibration or reversal of stresses
(unless such reversal is due solely to wind
forces)
8.1.5
Electrodes
The electrodes required for metal arc
welding shall be covered electrodes and
shall conform to IS : 814.
8.2.
STEEL WORK IN SINGLE
SECTION FIXED INDEPENDENTLY
The steel work in single sections of R.S.
Joints, flats, Tees Angles fixed independently
with or without connecting plate, is described
in the subparas below.
8.2.1
Fabrication
The steel sections as specified shall be
straightened and cut square to correct
lengths and measured with a steel tape. The
cut ends exposed to view shall be finished
smooth. No two pieces shall be welded or
otherwise jointed to make up the required
length of a member.
All straightening and shaping to form, shall
be done by pressure. Bending or cutting
shall be carried out in such a manner as not
to impair the strength of the metal.
8.2.2.
Painting
All surfaces which are to be painted, oiled or
otherwise treated shall be dry and thoroughly
cleaned to remove all loose scale and loose
rust.
Surfaces not in contact but
inaccessible after shop assembly, shall
receive the full specified protective treatment
before assembly which will involve two or
more coats of paint. This does not apply to
the interior or sealed hollow sections. Part to
be encased in concrete shall not be painted
or oiled. A priming coat of approved steel
primer i.e. Red Oxide Zinc chrome primer

conforming to IS : 2074 or as specified shall
be applied before any member of steel
structure is placed in position or taken out of
workshop.
8.2.3.
Erection
Steel work shall be hoisted and placed in
position carefully without any damage to
itself and other building work and injury to
workmen. Where necessary, mechanical
appliances such as lifting tackle winch etc.,
shall be used. The suitability and capacity
of all plant and equipment used for erection
shall be to the satisfaction of the Engineer.
8.2.4.
Measurements
The work as fixed in place shall be measured
in running metres correct to a millimeter and
weights calculated on the basis of standard
tables correct to the nearest kilogram.
Unless otherwise specified, weight of cleats,
brackets, packing pieces, bolts, buts,
washers, distance pieces, separators,
diaphragm gussets (taking overall square
dimensions), fish plates, etc., shall be added
to the weight of respective items. Payment
for holding down bolts and anchor channels
shall be made separately. No deduction shall
be made for skew cuts. In riveted work,
allowance is to be made for weight of rivet
heads.
Unless otherwise specified, an
addition of 3 per cent of the weight of
structure shall be made for shop and site
rivet heads in riveted steel structures. No
deduction shall be made for rivet/or bolt
holes (excluding holes for anchor or holding
down bolts). Deduction in case of rivet or
bolt hole shall however be made if its area
exceeds 0.02 sqm.
The weight of steel sheets, plates and strips
shall be taken from relevant Indian
2
Standards based on 7.85 kg/m for every
millimetre sheet thickness.
For rolled
sections, steel rods and steel strips, weight
given in relevant Indian Standards shall be
used.
8.2.5.
Rate
The rate includes the cost of all labour and
materials including the cost of steel, rivets,
bolts and service bolts, required for all the
operations described above except painting.
This will include only the steel work where
single sections are used except steel work
with rails. It will exclude the steel work in built
up sections, trusses and framed work, where
riveting, bolting or welding is involved. Cost
of painting primary coat is included in the
rate. Unless otherwise specified, the rates
include the supply, erection and removal of
scaffodling, machinery, hoisting, gear,

derricks, ropes, pulleys, tools, plants and all
consumable materials such as coal, oil etc.
8.3.
STEEL WORK IN BUILT UP
SECTIONS (RIVETTED AND BOLTED)
The steel work in built up sections (Riveted
and bolted) such as in trusses, framed work
etc., is specified in the subparas below.
8.3.1.
Laying Out
A figure of the steel structure to be fabricated
shall be drawn on a level platform to full
scale. This may be done in full or in parts,
as shown on drawings or as directed by the
Engineer. Steel tape shall be used for
measurements.
8.3.2.
Fabrication
Fabrication shall generally be done as
specified in IS : 800. In major works or where
so specified, shop drawings giving complete
information for the fabrication of the
component parts of the structure including
the location, type, size, length and details of
rivets, bolts or welds, shall be prepared in
advance of the actual fabrication and
approved by the Engineer. The drawings
shall indicate the shop and field rivets, bolts
and welds. The steel members shall be
distinctly marked or stenciled with paint with
the identification marks as given in the shop
drawings.
Great accuracy shall be observed in the
fabrication of various members, so that these
can be assembled without being unduly
packed, strained or forced into position and
when built up, shall be true and free from
twist, kinks, buckles or open joints.
Wooden or metal sheet templates shall be
made to correspond to each member and
position of rivet holes shall be marked
accurately on them and holes drilled. The

templates shall then be laid on the steel
members, and holes for riveting or bolting
marked on them. The ends of the steel
members shall also be marked for cutting as
per required dimensions. The base of steel
columns and the positions of anchor bolts
shall be carefully set out at the required
locations.
8.3.2.1.
The steel section shall be
straight or be straightened or flattened by
pressure unless required to be of curvilinear
form and shall be free from twists. These
shall be cut square either by shearing or
sawing to correct length and measured by
steel tape. No two pieces shall be welded or
joined to make up for the required length of
member.
8.3.2.2.
Making Holes: Holes through
more than one thickness of material for
members, such as compound stanchion and
girder flanges shall, where possible, be
drilled after the members are assembled and
tightly clamped or bolted together. Punching
may be permitted before assembly, provided
the holes are punched 3 mm less in diameter
then the required size and reamed after
assembly to the full diameter. The thickness
of material punched shall be not greater than
16 mm.
Rivet Holes: The diameter for rivets and
black bolts shall be taken as the nominal
diameter of a rivet plus 1.5 mm for rivets of
nominal diameter less than or equal to 25
mm and 2.0 mm for rivets of nominal
diameter exceeding 25 mm, unless specified
otherwise. Holes for turned and fitted bolts
shall be drilled or reamed large by 0.2 to 8
mm depending upon the dia. of bolts as
shown in Table 8.1.
TABLE 8.1
HOLES FOR TURNED AND FITTED BOLTS
Bolt diameter
Hole diameter
Bolt diameter
Hole diameter
1.6
1.8
(39)
42
2.4
42
45
(2.2)
2.6
(45)
48
2.5
2.9
48
52
3.4
(52)
56
(3.5)
4.0
(56)
62
4.5
(60)
66
(4.5)
5.0
64
70
Note:
5.5
(68)
74
6.6
72
78
(7)
7.6
(76)
82
9.0
80
86
10
11.0
(85)
91
12
14.0
90
96
(14)
16.0
(95)
101
16
18.0
100
107
(18)
20.0
105
112
20
22.0
110
117
(22)
24.0
(115)
122
24
26.0
120
127
(27)
30.0
125
132
30
33.0
(130)
137
(33)
36.0
140
147
36
39.0
(150)
158
1) All dimensions are in millimetres

2) Diameters in parenthesis are to
be treated as second preference.
Holes shall have their axis perpendicular to
the surface bored through. The drilling or
reaming shall be free from burrs, and the
holes shall be clean and accurate. Holes for
rivets and bolts shall not be formed by gas
cutting process. Holes for counter sunk bolts
shall be made in such a manner that their
heads sit flush with the surface after fixing.
8.3.2.3.Assembly : Before making holes in
individual members for fabrication, steel work
intended to be riveted or bolted together
shall be assembled and clamped properly
and tightly so as to ensure close abutting or
lapping of the surfaces of the different
members. All stiffeners shall bear tightly both
at top and bottom without being drawn or
caulked. The abutting joints shall be cut or
dressed true and straight, and fitted close
together. Before riveting or bolting up finally,
the members shall be taken apart and all
burrs removed.
Web plates of girders which have no cover
plates, shall have their ends flush with the
tops of angles unless otherwise required.
The web plates when spliced, shall have
clearance of not more than 5 mm. The
erection clearance for cleated ends of
members connecting steel shall preferably
be not greater than 1.5 mm. The erection
clearance at the ends of beams without web
cleats shall not be more than 3 mm at each
end but where for practical reasons, greater

clearance is necessary suitably designed
seating shall be provided.
Column splices and butt joints of struts and
compression members depending on contact
for stress transmission shall be accurately,
machined and close butted over the whole
section. In column caps and bases, the ends
of shafts together with the attached gussets,
angles, channels etc., after riveting together
shall be accurately machined so that the
parts connected butt against each other over
the entire surfaces of contact. Connecting
angels or channels shall be fabricated and
placed in position with great accuracy so that
they are not unduly reduced in thickness by
machining. The ends of all bearing stiffeners
shall be machined or grounded to fit tightly
both at top and bottom.
8.3.2.4.Rivetting: (a) Rivets shall be used,
where the connection is such that slip under
load has to be avoided.
(b) Preliminaries before riveting : Members to
be riveted shall have all parts firmly drawn
and held together before and during riveting.
Special care shall be taken in this respect for
all single riveted connections. For multiple
riveted connections, a service bolt shall be
provided in every third or fourth hole.
(c) Drifting of holes shall not be permitted
except to draw the parts together and the
drifting tool so used shall have its maximum
diameter not exceeding the nominal diameter
of rivet or bolt.
Drifting done during
assembling shall not distort the metal or

enlarge the holes.
(d) The work shall be got approved from the
Engineer before rivetting is commenced. It
shall be ensured that the alignment is
correct, the vertical plumb, the camber
correct with all camber jacks screwed tight
where applicable, all joint and cover plates in
correct position, service bolts tight and drifts
driven and field rivet holes coinciding.
(e) Process of riveting : The riveting shall be
carried out by using machines of the steady
pressure type.
However, where such
facilities are not available, hand riveting may
be permitted by the Engineer. The rivets
shall be heated red hot, care being taken to
control the temperature of heating so as not
to burn the steel.. Rivets of diameter less
than 10 mm may be driven cold. Rivets shall
be finished neat, with heads full and of equal
size. The heads shall be central on shanks
and shall grip the assembled members
firmly. All loose, burnt or badly formed rivets
with eccentric or deficient heads shall be cut
out and replaced. In cutting out rivets, care
shall be taken so as not to injure the
assembled members.
Caulking and
recapping shall not be permitted.
All
surplus materials round the rivet heads shall
be removed by chipping after the rivets have
cooled.
(f) For testing rivets, a hammer weighing
approx. 0.25 kg. shall be used and both
heads of the rivet (specially the machine
head) shall be tapped. When so tested, the
rivets shall not give a hollow sound and a jar.
Where so specified, other tests shall be
carried out to check the soundness of rivet.
All rivets heads shall be painted with
approved steel primer paint within a week of
their fixing.
(g) All tightened up, recapped or recauked
rivets or rivets with split heads shall be
replaced.
(h) Loose rivets and rivets not passed shall
be painted white on head and shall be
replaced at once, care being taken not to
disturb the adjacent rivets.
(i) Counter sunk rivets shall be inspected
after chipping heads and no unnecessary
chipping shall be permitted.
(j) With the prior approval of Engineer, for
rivet holes made in places where it is
impossible to rivet effectively, the hole may
be fitted with a machine or turned bolt and
the end of the bolt hammered down over the
tightened nut to prevent the latter working
loose.
(k) Tools and plants will not be supplied by

the Railway, unless definitely specified. The
contractor shall also arrange free of cost the
coal required for heating the rivets and will
erect and maintain all staging as necessary.
He will also do all petty repairs to snaps and
other tools which may be supplied to him by
the Railway.
8.3.2.5. Bolting: (a) The nominal length of
the bolt shall be the distance from the
underside of the head to the farther end of
the shank. The nominal diameter of the bolt
shall be the diameter at the shank above the
screwed threads. Bolts, nuts and washers
shall be thoroughly cleaned and dipped in
double boiled linseed oil, before use. The
linseed oil should be supplied by the
Contractor and nothing extra shall be paid for
this. All bolt heads and nuts shall be
hexagonal unless specified otherwise. The
screwed threads shall conform to IS : 1363
and the threaded surface shall not be
tapered. The bolts shall be of such length as
to project at least two clear threads beyond
the nuts when fixed in position, and these
shall fit in the holes without any shake. The
nuts shall fit in the threaded ends of bolts
properly.
(b) Where necessary, washers shall be
tapered or otherwise suitably shaped to give
the heads and nuts of bolts a satisfactory
bearing. The threaded portion of each bolt
shall project through the nut at least two
threads. In all cases where the full bearing
area of the bolt is to be developed, the bolt
shall be provided with a washer of sufficient
thickness under the nuts to avoid any
threaded portion of the bolt being within the
thickness of the parts bolted together.
(c) Where there is a risk of the nuts being
removed or becoming loose due to vibrations
or reversal of stresses, these shall be
secured from slackening by the use of lock
nuts, spring washers or as directed by the
Engineer.
(d) Where turned and fitted bolts are required
to be used in place of rivets, these shall be
provided with washers not less than 6mm
thick, so that the nut, when tightened, shall
not bear on the unthreaded body of the bolt.
Tapered washers shall be provided for all
heads and nuts bearing on levelled surfaces.
The threaded portion of the bolt shall not be
within the thickness of the parts bolted
together. The faces of bolt heads and nuts
abutting against steel members shall be
machine finished.
8.3.3. Erection
8.3.3.1 Steel work shall be hoisted and

erected in position carefully, without any
damage to itself other structures and
equipment and injury to workmen. The
method of hoisting and erection proposed to
be adopted by the contractor shall be got
approved from the Engineer in advance.
The contractor, however shall be fully
responsible for the work being carried out in
a safe and proper manner without unduly
stressing the various members. Proper
equipment such as derricks, lifting tackles,
winches, ropes etc., shall be used.
8.3.3.2 The work may be erected in suitable
units as may be directed by the Engineer.
Fabricated members shall be lifted at such
points as to avoid deformation or excessive
stress in members. The structure or part of it
placed in position shall be secured against
over-turning or collapse by suitable means.
During execution, the steel work shall be
securely bolted or otherwise fastened and
when necessary temporarily braced to
provide for all loads to be carried safely by
the structure during erection including those
due to erection equipments and their
operations. The steel work shall be placed in
proper position as per approved drawing.
Final riveting or permanent bolting shall be
done only after proper alignment has been
checked and confirmed.
8.3.3.3 Trusses shall be lifted only at nodes.
The trusses above 10 m in span shall not be
lifted by slinging at two mid points of rafters,
unless temporarily braced by a wooden
member of a suitable section. After the
trusses are placed in position, purlins and
wind bracings shall be fixed as soon as
possible.
The end of the truss which faces the
prevailing winds shall be fixed with holding
down bolts, and the other end kept free to
move. In case of trusses of spans up to 10 m
the free end of the truss shall be laid on lead
sheet or steel plate as per design and the
holes for holding down bolts shall be made in
the form of oblong slots so as to permit the
free movements of the truss end. For large
spans the truss shall be provided with proper
bearings as per design.
8.3.3.4 Columns and stanchions shall be
erected truly vertical with the necessary
cross bracing etc., and the base shall be
properly fixed with the foundation concrete
by means of anchor bolts etc., as per
drawing.
8.3.3.5 Anchor bolts to be placed in the
concrete foundation should be held in
position with a wooden template. At the time
of concreting, anchor bolt locations shall be

provided with suitable timber mould or pipe
sleeve to allow for adjustment which shall be
removed after initial setting of concrete. The
spaces left around anchor bolts shall be
linked to a stopping channel in the concrete
leading to the side of the pedestal and on the
underside of the base plate to allow the
spaces being grouted up after the base plate
is fixed in position along with the column
footing. Grouting shall be of cement mortar
1:3 (1 cement : 3 coarse sand) or as
specified.
8.3.3.6 Bedding of Column, Stanchions Etc.,
: Bedding shall not be carried out until the
steel work has been finally levelled, plumbed
and connected together. The stanchion shall
be supported on steel wedges and adjusted
to make the column plumb. For multistoreyed buildings, the bedding shall not be
done until sufficient number of bottom
lengths of stanchions have been properly
lined, levelled and plumbed and sufficient
floor beams are fixed in position. The base
plates shall be wedged clear of the plumbed
and sufficient floor beams are fixed in
position. The base plates shall be wedged
clear of the bases by M.S. wedges and
adjusted where necessary to plumb the
columns. The gaps under the base plate
which may be up to 25 mm shall then be
pressure grouted with cement grout.
With small columns, if permitted by the
Engineer, the column base shall be floated
on a thick cement grout on the concrete
pedestal. The anchor bolt holes in the base
plate may be made about 10 to 15 mm larger
than the bolts.
In such cases suitable
washers shall be provided.
8.3.4. Painting
Before the members of the steel structure
are placed in position or taken out of the
workshop these shall be painted as specified
in para 8.2.2. Subsequent coat or coats of
paint shall be applied after all the members
are finally fixed in position.
8.3.5 Measrements:- Provisions in Para
8.2.4 will apply.
8.3.6 Rate
The rate for the item shall include the cost of
all labour and materials including the cost of
steel, rivets, bolts and service bolts required
for all the operations of the work as
described above except painting of final
coats. Cost of painting primary coat is
included with rate. Purlins and wind bracings
shall be paid for separately as steel work in
single sections. Cleats, when forming part of
the trusses, shall be paid for under this item.

When the cleats are required to be
manufactured and erected for an existing
truss, payment for the same shall be made
as steel work in single sections. The rates
include the supply erection and removal of
scaffolding, machinery, hoisting gear,
derricks, ropes, pulleys, tools, plants and all
consumable materials such as coal, oil etc.
Painting of the final coat / coats of the steel
work shall be paid for separately.
8.4 STEEL WORK IN BUILT UP SECTION
(WELDED)
The steel work in built up sections (welded)
such as trusses, framed work etc., has been
described in the subparas below.
8.4.1 Laying out - It shall be as specified in
para 8.3.1.
8.4.2 Fabrication, Erection & Painting
8.4.2.1.
Straightening, shaping to form,
cutting and assembling, shall be as per para
8.3.2. as far as applicable, except that the
words riveted or bolted shall be read as
welded and holes shall only be used for the
bolts used for temporary fastening as shown
in drawings.
8.4.2.2.
Welding
:
Welding
shall
generally be done by electric arc process as
per IS : 816 as it is economical. Where
electric supply is not available, generators
shall be arranged by the contractor at his
own cost unless otherwise specified. Gas
welding shall only be resorted to using
oxyacetylene flame with the specific approval
of the Engineer. Gas welding shall not
however be permitted for structural steel
work. Gas welding requires heating of the
members to be welded along with the
welding rod and is likely to create
temperature stresses in the welded
members. Precautions shall therefore be
taken to avoid distortion of the members due
to these temperatures stresses.
The work shall be done as shown in the shop
drawings which should clearly indicate
various details of the joint to be welded, type
of welds, shop and site welds as well as the
types of electrodes to be used. Symbol for
welding on plane and shops drawings shall
be according to IS : 813.
As far as possible every effort shall be made
to limit the welding that must be done after
the structure is erected so as to avoid the
improper welding that is likely to be done due
to heights and difficult positions on
scaffolding etc., apart from the aspect of
economy. The maximum dia of electrodes for
welding any work shall be as per IS : 814.

Joint surfaces which are to be welded
together shall be free from loose mill scale,
rust, paint, grease or other foreign matter,
which adversely affects the quality of weld
and workmanship.
8.4.2.3.
Precautions:
All operations
connected with welding and cutting
equipment shall conform to the safety
requirements given in IS : 818 for Safety
requirements and Health Provision in Electric
and gas welding and cutting operations.
8.4.2.4.
Operation, Workmanship and
Process of Welding are described in
Annexure 8.2.
8.4.2.5.
Inspection and testing of welds
shall be as per IS : 822.
8.4.2.6.
Assembly : Before welding is
commenced, the members to be welded
shall first be brought together and firmly
clamped or tack welded to be held in
position. This temporary connection has to
be strong enough to hold the parts
accurately in place without any disturbance.
Tack welds located in places where final
welds will be made later shall conform to the
final weld in quality and shall be cleaned off
slag before final weld is made.
8.4.2.7.
Erection : The specifications
shall be as described in para 8.3.3. except
that while erecting a welded structure
adequate means shall be employed for
temporary fastening of the members together
and bracing the frame work until the joints
are welded. Such means shall consist of
erection bolts, tack welding or other positive
devices imparting sufficient strength and
stiffness to resist all temporary loads and
lateral forces including wind. Owing to the
small number of bolts ordinarily employed for
joints which are to be welded, the temporary
support of heavy girders carrying columns
shall be specially checked. Different
members which shall be fillet welded, shall
be brought into as close contact as possible.
The gap due to faulty workmanship or
incorrect fit if any shall not exceed 1.5 mm.
If gap exceeds 1.5mm or more gap occurs
locally the size of fillet weld shall be
increased at such position by an amount
equal to the width of the gap.
8.4.2.8.
Painting : Before the members
of the steel structures are placed in position
or taken out of the workshop these shall be
painted as specified in para 8.2.2.
8.4.3.
Measurements
The mode of measurements shall be the
same as specified in para 8.2.4. except that
weight of welding material shall not be added

in the weight of members for payment and
nothing extra shall be paid for making and
filling holes for temporary fastening of
members during erection before welding.
8.4.4. Rate
The rate shall include the cost of all labour
and materials involved in all the operations
described above and as described in para
8.3.6.
8.5. COLLAPSIBLE GATES (For details
refer Figure 8.2)
8.5.1. Types & Components : These shall
be of approved manufacture and shall be
fabricated from the mild steel sections. The
gates shall consist of double or single
collapsible gates depending on the size of
the opening. These shall consist of vertical
double channels each 20 x 10 x 2 mm at 10
cm centres braced with flat iron diagonals 20
x 5 mm and top and bottom rails of T-iron 40
x 40 x 6 mm @ 3.5 kg/m with 40 mm dia. ball
bearings in every fourth double channel,
unless otherwise specified.
Wherever
collapsible gate is not provided within the
opening and fixed along the outer surface.
T-iron at the top may be replaced by flat iron
40 x 10 mm.
The collapsible gate shall be provided with
necessary
bolts
and
nuts,
locking
arrangement, stoppers and handles. Any
special fittings like spring, catches and locks,
shall be so specified in the description of
item where so required. The gate shall open
and close smoothly and easily.
8.5.2. Fixing
T-iron rails shall be fixed to the floor and to
the lintel at top by means of anchor bolts
embedded in cement concrete of floor and
lintel. The anchor bolts shall be placed
approximately at 45 cm centres alternatively
in the two flanges of the T-iron. The bottom
runner (T-iron) shall be embedded in the
floor and proper groove shall be formed
along the runner for the purpose. The
collapsible shutter shall be fixed at sides by
fixing the end double channels with T-iron
rails and also by hold-fasts bolted to the end
double channel and fixed in masonry of the
side walls on the other side. In case the
collapsible shutter is not required to reach
the lintel, beam or slab level, a Tee-section
suitably designed may be fixed at the top,
embedded in masonry and provided with
necessary clamps and roller arrangement at
the top. All the adjoining work damaged in
fixing of gate shall be made good to match

the existing work, without any extra cost.
8.5.3. Painting
All the members of the collapsible gate
including T-iron shall be thoroughly cleaned
off rust, scales, dust etc., and given a
priming coat of approved steel primer i.e. red
oxide zinc chrome primer conforming to IS :
2074 or as specified before fixing them in
position.
8.5.4. Measurements
The height and breadth shall be measured
correct to a cm. The height of the gate shall
be measured as the length of the double
channels and breadth from outside to outside
of the end fixed double channels in open
position, of the gate. The area shall be
calculated in square metres, correct to two
places of decimal.
8.5.5. Rate
described above.
8.6. M.S. SHEET SLIDING SHUTTERS
(Refer Figure 8.3A)
8.6.1. Types & Components:- These shall
be manufactured as per drawings and
specifications. These shall be fabricated
from mild steel sheets. The shutters shall
be double or single leaf shutter as specified.
The shutters shall be fabricated of specified
size of M.S. angle iron frame diagonally
braced with the same size of M.S. angle and
riveted together with 3 mm gusset plate at
junction to form a rigid frame M.S. sheet of 1
mm thickness or as specified shall be fixed
to the frame with rivets, as approved by the
Engineer. These shall also be provided with
top and bottom guide rails of specified size
angles or T-irons and 25 mm diameter pulley
or with 25 mm diameter ball bearing at the
bottom and guide back with steel pulleys at
the top. The shutters shall also be provided
with locking arrangement, handles, stoppers,
holdfasts and other fittings as specified in the
description of the item.
The guide rails shall be sufficiently long and
continued along the wall on both ends so
that the sliding shutters can rest against the
walls, giving full opening when so required.
8.6.2. Fixing
The guide rails shall be fixed to the floor by
means of anchor bolts embedded in the
floor. The steel section at the top shall be
suitably supported from the walls. Two
channel sections shall be suitably fixed
vertically below the extreme clamps in the

wall and floor to avoid the shutter from going
out of the supports at top and bottom. A
suitable clamping arrangement will be
provided at either end of the opening to
avoid the shutters from rolling back into the
opening. All the adjoining work damaged in
fixing shall be made good to match the
existing work.
8.6.3.
Painting
All members of the sliding shutters including
fittings shall be thoroughly cleaned of rust,
scales, dust etc., and given a priming coat of
approved steel primer i.e. Red oxide chrome
primer conforming to IS : 2074 or as
specified before fixing them in position.
8.6.4.
Measurements
The height and breadth shall be measured
correct to a cm. and its area for payment
shall be calculated in square metres correct
to two places of decimal. The height of the
shutter shall be measured from outside to
outside of the guide rail and width outside to
outside of the shutter including the vertical
position channels in sides, when closed.
8.6.5.
Rate
described above.
8.7. M.S. SHEET SIDE HUNG SHUTTERS
(REFER FIGURE 8.3B)
8.7.1.Types & Components:- These shall
be manufactured as per drawing and
specifications. These shall be fabricated from
mild steel sheets and angle iron. The doors
shall be provided as double leaf shutters
unless otherwise specified. The shutters
shall be fabricated with frame of M.S. angle
40 x 10 x 6 mm @ 3.5 kg/metre and two
diagonal braces of the same section as
shown in Figure 8.3B unless otherwise
specified. The frame shall be riveted and/or
welded at the junctions. Wherever riveting
shall be done 3 mm gusset plate shall be
provided at the junctions. M.S. sheet of 1
mm thickness, shall be fixed to the frame
with rivets as approved by the Engineer.
Alternatively the diagonal bracing may be
replaced by one horizontal and two cross
flats 30 x 6 mm unless otherwise specified.
The outer frame shall be provided with cleats
made of section 40 x 40 mm and bent in the
shape of angle cleats with one arm 150 mm
long and the other arm 50 mm long and fixed
to the angle iron frame of the door with two
12 mm dia bolts and nuts, For doors up to
2.40 m height, two angle cleats per door
shall be provided.
The cleat shall have a vertical leg of 150 mm

which shall be fixed with frame and
horizontal leg of about 50 mm which shall be
provided with a hole of 24 mm dia and fixed
in the projected pin of the pin clamp.
8.7.2.
Fittings and Fixtures
The shutter shall be fixed to the wall
masonry with four pin clamps (pintles) where
the height of the shutter is up to 2.4 m. Each
pin clamp shall consist of 50 x 6 mm flat iron
45 cm long bent and forked at one end and
provided with 20 mm diameter. M.S. pin on
the other. The pin shall be firmly riveted or
welded to the pin clamp, the other end of
which shall be embedded in masonry by
means of cement concrete block 40 x 20 x
20 cm of 1:2:4 mix (1 cement : 2 coarse sand
: 4 graded stone aggregate 20 mm normal
size). It shall be so placed that bottom pin
shall face towards and Top pin downward in
order that the gate may not be removed by
lifting over pins.
One hook with eye 45 cm long of 10 mm
diameter shall be provided for each shutter
to keep it fixed in open position. The hook
shall be fixed in wall masonry with wooden
block and the eye shall be fixed on 6 mm
thick M.S. plate as staple and fixed in the
shutter frame with rivet or weld.
A cement concrete block 15 x 10 x 20 cm in
1:2:4 (1 cement : 2 coarse Sand : 4 Graded
Stone aggregate of 20 mm nominal size) mix
shall be embedded in the floor or at junction
of two shutters so that door shutters, open
only on the outside and not on the inside.
The shutters shall also be provided with
locking arrangement and two handles of the
shape and pattern as approved by the
Engineer.
8.7.3.
Painting
All the members of the door including angle
iron shall be thoroughly cleaned off rust,
scales, dust etc., and given a priming coat of
approved steel primer i.e. Red Oxide Zinc
specified before fixing them in position.
8.7.4.
Measurements
The width and height of shutters shall be
measured to the nearest cm. The area shall
be calculated in square metre correct to two
places of decimal.
8.7.5.
Rate
described above. Nothing extra shall be paid
for cement concrete blocks or wooden blocks
nor anything deducted for these from the
measurement of the masonry wall.
8.8. ROLLING SHUTTERS

8.8.1. General :
8.8.1.1
Rolling shutters shall conform to
IS : 6248. These shall include necessary
locking arrangement and handles etc.,
These shall be suitable for fixing in the
position, which may be one of the following
as specified
1.
Fixture on the inside, above bottom of
lintel, with guides on the inside face of wall.
2.
Fixture on the outside, above bottom of
lintel, with guides on the outside face of wall.
3.
Fixture on the outside, below bottom of
lintel, with guides on the outside face of wall.
4.
Fixture under the lintel, with guides on
the jambs.
5.
Fixture on the inside, below bottom of
lintel, with guides on the inside face of wall.
The door shall be either of push and pull type
or operated with mechanical device supplied
by the manufacturer. Shutters up to 10 sq.
metre shall be of push and pull type and
shutters with an area of over 10 sq. metre
shall generally be provided with reduction
gear operated by mechanical device with
chain or handle. If bearings are specified for
ease of operation, these shall be paid for
separately.
8.8.1.2.
Shutter : The shutter shall be
built up of inter-locking lath section formed
from cold rolled steel strips. The thickness of
the sheets from which the lath sections have
been rolled shall be not less than 0.90 mm
for the shutters up to 3.5 metre width and not
less than 1.20 mm for shutters above 3.5 m
width. Shutters above 9 metres in width
should be divided in 2 parts with provision of
one middle fixed or movable guide channel
or supported from the back side to resist
wind pressure. The lath section shall be
rolled so as to have interlocking curls at both
edges and a deep corrugation at the centre
with a bridge depth of not less than 12 mm to
provide sufficient curtain of stiffness for
resisting manual pressures and normal wind
pressure. Each lath section shall be a
continuous single piece without any welded
joint. When interlocked, the lath sections
shall have a distance of 75 mm rolling
centres. Each alternate lath section is fitted
with malleable cast iron or mild steel clips
securely riveted at either ends, thus locking
Clear width of shutters
the lath section at both ends and preventing

lateral movement of the individual lath
sections. The clips shall be so designed as
to fit the contour of the lath sections.
8.8.1.3.
Spring:- The spring shall be of
coiled
type.
The
spring
shall
be
manufactured from high tensile spring steel
wire or strips of adequate strength
conforming to IS : 4454 Part I.
8.8.1.4.
Roller and Brackets:
The
suspension shaft of the roller shall be made
of steel pipe conforming to heavy duty as per
IS : 1161. For shutter up to 6 metre width
and height not exceeding 5 metre, steel
pipes of 50 mm nominal bore shall be used.
The shaft shall be supported on mild steel
brackets of size 375 x 375 x 3.15 mm, for
shutters up to a clear height of 3.5 metre.
The size of mild steel brackets shall be 500 x
500 x 10 mm for shutters of clear height
above 3.5 m and up to 6.5 m.
The
suspension shaft clamped to the brackets
shall be fitted with rotatable cast iron pulleys
to which the shutter is attached. The pulleys
and pipe shaft shall be connected by means
of pre-tensioned helical springs to counterbalance the weight of the shutter and to keep
the shutter in equilibrium in any partly open
position
8.8.1.5.
When the width of the opening is
greater than 3.5 mtr, the cast iron pulleys
shall be inter-connected with a cage formed
out of mild steel flats of at least 32 x 6 mm
and mild steel dummy rings made of similar
flats to distribute the torque uniformly. Self
aligning two row ball bearings with special
cast iron casings shall be provided at the
extreme pulley and caging rings shall have a
minimum spacing of 15 mm and at least 4
number flats running throughout length of
roller shall be provided.
8.8.1.6.
In case of shutters of large
opening with mechanical device for opening
the shutter the roller shall be fitted with a
purion wheel at one end in contact with a
worm fitted to the bracket plate, caging and
pulley with two ball bearings shall be
provided.
8.8.1.7.
Guide Channel : The width of
guide channel shall be 25 mm and the
minimum depth of guide channels shall be as
follows :
Depth of guide channel
Up to 3.5 m
65 mm
3.5 m up to 8 m
75 mm
8 m and above
100 mm
8.8.1.8.
The gap between the two legs of
the guide channels shall be sufficient to allow
the free movement of the shutter and at the
same time close enough to prevent rattling of
the shutter due to wind.
8.8.1.9.
Each guide channel shall be
provided with a minimum of three fixing
cleats or supports for attachment to the walls
or column by means of bolts or screws. The
spacing of cleats shall not exceed 0.75 m.
Alternatively, the guide channels may also
be provided with suitable dowels, hooks or
pins for embedding in the walls.
8.8.1.10.
The guide channels shall be
attached to the jambs, plumb and true either
in the over-lapping fashion or embedded in
grooves, depending on the method of fixing.
8.8.1.11.
Cover: Top cover shall be of mild
steel sheets not less than 0.90 mm thick and
stiffened with angle or flat stiffeners at top
and bottom edges to retain shape.
8.8.1.12.
Lock plates with sliding bolts,
handles and anchoring rods shall be as per
IS : 6248.
8.8.2.
Fixing
8.8.2.1
The arrangement for fixing in
different situations in the opening shall be as
per IS : 6248.
8.8.2.2.
Brackets shall be fixed on the
lintel or under the lintel as specified with rawl
plugs and screws, bolts etc., The shaft along
with the spring shall then be fixed on the
brackets.
8.8.2.3
The lath portion (shutter) shall
be laid on ground and the side guide
channels shall be bound with ropes etc., The
shutter shall then be placed in position and
top fixed with pipe shaft with bolts and nuts.
The side guide channels and cover frames
shall then be fixed to the walls through the
plate welded to the guides. These plates
and bracket shall be fixed by means of steel
screws bolts, and rawl plugs concealed in
plaster to make their location invisible. Fixing
shall be done accurately in a workman- like
manner so that the operation of the shutter is
easy and smooth.
8.8.3.
Measurements
The actual area of rolling shutters shall be
measured in square metres correct to two
places of decimals. The width shall be
measured as the width of the shutter

including portions hidden in the guide
channels and height shall be measured as
the length of the shutter from the bottom of
the locking plate to the top of the laths
including portion above the opening. The
area shall be calculated in square metres
correct to two places of decimal.
8.8.4.
Rate
The rate shall include the cost of materials
and labour involved in all the operations
described above including cost of top cover
and spring except ball bearing and
mechanical device of chain and crank
operation, which shall be paid for separately.
8.9.
ROLLING GRILLS
8.9.1
General :
(a) Rolling grill is meant to provide visibility
or ventilation or both though the degree of
protection and safety is less as compared to
a rolling shutter. In the situations where a
certain amount of ventilation combined with
safety is required, rolling shutter-cum-grill
may be provided in which the rolling shutter
may have rolling grill portion either at the top
or at the bottom or at both places. The
rolling grill portion may also be provided in
the middle of the shutter. The total height of
the grill portion in all the segments of rolling
shutter-cum-grill shall not exceed 1.0 m and
the height of the grill portion in any individual
segment shall not be more than 0.5 m.
(b) Rolling grills are similar in design,
construction and operation to rolling shutters
and all he provisions of para 8.8 shall be
applicable to rolling grills which shall also
conform to IS : 6248.
8.9.2.
Shutters
Rolling grill shutter and the rolling grill portion
of the rolling shutter-cum-grill shall be
fabricated with 8 mm diameter mild steel
round bars. Straight bars and bars bent to
the required profile are placed alternatively
and held in position with 20 mm wide and 5
mm thick mild steel flat links. Straight bars
shall be spaced not exceeding 150 mm
centre to centre and the bars bent to
required profile shall be placed symmetrically
between two consecutive straight bars.
Unless otherwise specified or directed by the
Engineer, bars placed alternately with
straight bars shall be bent to form a

corrugated profile such that the pitch of the
corrugation is 100 to 120 mm and the depth
of corrugation is 80 to 100 mm. All the bent
bars shall have uniform profile. Straight bar
along with the adjoining bent bars on both
sides shall be held in position by passing the
bars through holes in the links. Each link
shall have three holes and the length of the
links shall be such that the distance from the
centre of the hole to the nearest edge of the
flat is not less than the diameter of the hole.
The corner of the links shall be rounded. All
links shall be of uniform size and shape. The
spacing of the links measured along the
straight bar shall be of uniform size and
shape and shall be the same as centre to
centre distance between two consecutive
crests/troughs of the bars bent to the
required profile. Each bar and link shall be a
continuous single piece without any joint.
8.9.3.
Measurements and Rate
The measurements and rate shall be as
specified in paras 8.8.3. and 8.8.4
respectively. In case of Rolling Shutter-cumGrill, where the area of the grill portion is half
or less than half the area of opening, it shall
be measured and paid as rolling shutter and
where the area of grill portion is more than
half the area of opening, it shall be measured
and paid as rolling grill.
8.10.
STEEL DOORS, WINDOWS,
VENTILATORS AND COMPOSITE UNITS
(Refer Figure 8.4)
8.10.1
General
(a) Hot rolled steel /sections for fabrication
of steel doors, windows, ventilators and fixed
For
lights
including shapes, weights and
designations of the sections shall be as per
IS : 7452. Annexure 8.3 indicates the
purpose or the situation where the sections
are normally used. Tolerance in thickness of
the sections shall be + 0.2 mm. The steel
doors, windows, ventilators and composite
units shall be got fabricated in a workshop
approved by the Engineer.
(b) Steel doors, windows, ventilators and
sashes shall conform to Indian Standard
Specification No. IS 1038. The type, over all
sizes, side opening position of steel doors,
windows and ventilators shall be specified as
per details given in IS 1038. The provision of
a thresh hold or tie bar etc at the bottom of
the door frame shall also be specified.
Unless otherwise specified, the weight of the
different rolled steel sections used for the
manufacture of doors, windows, and
ventilators shall not be less than those
specified in IS 1038.
(c) Standard
sizes
and
their
designation
The overall sizes of standard doors, windows
and ventilators as per IS:1038 are derived
after allowing a clearance of 1.25 cm on all
the four sides for purpose of fitting them into
modular openings (i.e. openings with the
principal dimensions in multiples of the 10
cm module) In the case of doors, if threshold
at bottom of door opening is not to be
provided as is the present general practice,
there will be no need for a gap of 1.25 cm at
the bottom and the height of steel door may
be 1.25 cm instead of 2.5cm less than the
height of modular opening. The standard
sizes of openings prescribed for doors,
windows and ventilators are the following :
Standard Sizes of openings

Heights (cm)
Doors
210
Windows
90,120 and 150*
Ventilators
60
Widths (cm)
60, 80 and 120
60,100, 120, 150 and 180
60, 80, 100, 120, 150 and
180
(Note:- * Windows 150 cm in height are with fixed light above).

Doors, windows and ventilators are
designated by a sequence of symbols
denoting their width, type and height
respectively.
The width and height are
indicated in terms of the number of modules
and the type through a combination of two of
the following letters of the alphabet.
i)
ii)
Letter
H
N
C
S
T
Denoting
With horizontal glazing bars
Without horizontal glazing bars
Centre-hung shutters
Side-hung shutters
Top-hung shutters
F
Fixed glass panes.
A few examples of standard designations are
(a) Door 12 HS 21, (b) Window 12 HS/12
and (c) Ventilators 12 HF 6, as illustrated in
Figure 8.4 in the form of a combination of
the three which is jointly designated as
12 HF 6 / 12 HF 6
12 HS 21 / 12 HS 12
(d) Fittings : The following are the minimum
items to be supplied with steel doors,
windows, and ventilators:i)
Frames and Shutters (including
coupling sections, weather bars etc as
required)
ii)
Projecting hinges for shutters
iii)
Lugs or other fixing device as
necessary
iv)
One peg stay for each window shutter
and top-hung ventilator shutter
v)
One spring catch, cord eye and pulley
and 2 sets of pivots for each centre-hung
ventilator shutter
vi)
One handle for each window shutter
vii) One door handle for each door shutter
viii) Lock plate, with locking arrangements
for each door
ix)
Glazing clips (where necessary)
x)
Two drop-bolts for each door (for the
first closing shutter in double leaf doors)
The handle for window shutters shall have a
two point nose, with a striking plate on the
fixed frame to engage it either in the fast
position or in a slightly open position, when
the handle is turned. The fittings under items
(iv) to (vii) and (x) shall be of brass, bronze
or other non-ferrous metal mentioned in
IS:1038,
notwithstanding
steel
being
mentioned in some cases as a permitted
alternative.
e)
Tolerance in Size : The steel doors
and windows shall be according to the
specified sizes and design as indicated in (c)
above. The actual sizes of doors, windows
and ventilators shall not vary by more than +
1.5 mm from those given in the drawing.
8.10.2.
Fabrication
8.10.2.1.
Frames : Both the fixed and
opening frames of Hot rolled steel shall be
made of sections which have been cut to
length and mitred. The corner of fixed and
opening frames shall be welded to form a
solid fused welded joint conforming to the
requirements given below. All frames shall
be square and flat. The process of welding
adopted shall be flash butt welding or metal
arc welding or any other suitable method.

The section for glazing shall be tennoned
and riveted into the frames and where they
intersect the vertical tie shall be broached
and horizontal tie threads through it, and the
intersection closed by hydraulic pressure.
equirements of welded joints for steel
products:(i)
Visual Inspection Test - When two
opposite corners of the frame are cut, paint
removed and inspected, the joint shall
conform to the following:
(a) Welds should have been made all
along the place of meeting the members and
tack welding shall not be permitted.
(b) Welds should have been properly
grounded and
(c)
Complete cross section of the corner
shall be checked up to see that the joint is
completely solid and there are no cavities
visible.
(ii) Micro and Macro Examinations
From the two opposite corners obtained for
visual test, the flanges of the sections shall
be cut with the help of a saw. The cut
surface of the remaining portions shall be
polished, etched and examined. The
polished and etched faces of the weld and
the base metal shall be free from cracks and
reasonably free from under cutting, overlaps,
gross porosity and entrapped slag.
(iii) Fillet Weld Test
The fillet weld in the remaining portion of the
joint shall be fractured by hammering. The
fractured surfaces shall be free from slag
intrusion, porosity, crack penetration defects
and fusion defects.
8.10.2.2.
Door :
The hinges shall
normally be of 50 mm projecting type. Nonprojecting type hinges may also be used if
approved by the Engineer. The hinge pin
shall be of electro-galvanized steel or
aluminium alloy of suitable thickness and
size. Door handles shall be approved by the
Engineer. A suitable latch lock for door openable both from inside and outside shall be
provided.
In the case of double doors, the first closing
leaf shall be that the left hand leaf with
locking of the door from the push side. The
first closing shutter shall have a concealed
steel bolt at top and bottom. The bolts shall
be so constructed as not to work loose or
drop by its own weight.
Single and double shutter door may be
provided with a three way bolting device.
Where such device is provided in the case of
double shutters, concealed brass or steel

bolts shall not be provided.
8.10.2.3.
Windows
(a) For fixed windows, the frames shall be
fabricated as per para 8.10.2.1.
(b) Side hung windows
For fixing steel hinges, slots shall be cut in
the fixed frame and hinges inserted inside
and welded to the frame at the back. The
hinges shall normally be of projecting type
with thickness not less than 3.15 mm and
length not less than 65 mm and width not
more than 25 mm. Non projecting type
hinges may also be allowed if approved by
the Engineer. The diameter of hinge pins
shall not be less than 6 mm. The hinge pin
and washer shall be of galvanized steel or
aluminium alloy of suitable thickness.
For fixing hinges to inside frame, the method
described above may be adopted but the
weld shall be cleaned, or the holes made in
the inside frame and hinge riveted.
The handle of side hung shutters shall be
pressed brass, cast brass, aluminium or
steel protected against rusting and shall be
mounted on a steel plate. Thickness of
handle shall not be less than 3 mm in case of
steel or brass and 3.5 mm in case of
aluminium.
The handle plate shall be
welded, screwed and/or riveted to the
opening frame in such a manner that it
should be fixed before the shutter is glazed
and should not be easily removable after
glazing.
The handle shall have a two point nose
which shall engage with a brass or
aluminium alloy striking plate on the fixed
frame in a slightly opened position as well as
closed position. The boss of handle shall
incorporate a friction device to prevent the
handle from dropping under its own weight
and the assembly shall be so designed that
the rotation of the handle may not cause it to
unscrew from the pin.
The height of the handle plate in each type of
standard windows will be as specified.
Otherwise it shall be at a height of 3/8 of the
height of shutter, from its bottom. The strike
plate shall be designed and fixed in such a
position in relation to the handle that with the
later bearing against its stop, there shall be
adequately tight fit between the casement
and outer frames.
In case where no friction type hinges are
provided, the window shall be fitted with peg
stays which shall be either of black oxidized
steel, pressed or cast brass or as specified,
300 mm long with steel peg and lacking
brackets. The pegs stay shall have three

holes to open the side hung casement in
three different angles. The peg stay shall be
of minimum thickness 2 mm in case of brass
or aluminium and 1.25 mm in case of steel.
Where specified, Side hung shutters fitted
with friction hinges shall also be provided
with a peg stay.
If specified, side hung shutters may be
provided with an internal removable fly proof
screen in a 1.25 mm thick sheet steel frame
fitted to the outer frame of the shutter by
brass turn buckles at the jamb, and brass
studs at the sill to allow the screen being
readily removed.
The windows with
removable fly proof screen shall be fitted with
a through-the-screen level operator at the sill
level to permit the operation of the shutter
0
through an angle of 90 without having to
remove the fly proof screen. The lever shall
permit keeping the shutter open in minimum
three different positions.
8.10.2.4.
Ventilators
(a) Top Hung Ventilators - The steel butt
hinges for top hung ventilators shall be
riveted to the fixed frame or welded to it at
the back after cutting a slot in it. Hinges to
the opening frame shall be riveted or welded.
Top hung ventilators shall be provided with a
peg stay with three holes which when closed
shall be held tightly by the locking bracket.
The locking bracket shall either be fitted to
the fixed frames or to the window.
(b) Centre Hung Ventilators - Central hung
ventilators shall be hung on two pairs of
brass or aluminium cup pivots as specified,
riveted to the inner and outer frames of
ventilators to permit the ventilator shutter to
o
swing to an angle of approx 80 . The
opening portion of the ventilators shall be so
balanced that it remains open at any desired
angle under normal weather conditions.
8.10.2.4.1. A black oxidized steel spring
catch approved by the Engineer shall be
fitted in the centre of the top of the centre
hung ventilator, for the operation of
ventilators.
The spring catch shall be
secured to the frame with M.S. screws and
shall close into a mild steel or malleable iron
catch plate riveted, screwed or welded to the
outside of the outer window frame bar.
8.10.2.4.2. A black oxidized cord pulley
wheel in galvanized mild steel brackets shall
be fitted at sill of the centre hung window
with mild steel screws or alternatively welded
together with a mild steel or malleable iron
cord-eye riveted or welded to the bottom
inter frame bar of the window in a position

corresponding to that of pulley.
Removable fly-proof screen may be provided
as specified in para 8.10.2.3.(b). This shall
be fitted with a through-the-screen operator
to enable operating and keeping the shutter
open in minimum three different positions.
8.10.2.5.
Composite Units:
Composite
units consist of a combination of two or more
units of doors, windows and ventilators etc.,
as the case may be. The different units shall
be coupled by using coupling sections K-11B
or K-12B (Ref. Annexure 8.3) as the case
maybe.
Wherever the ventilators, windows and doors
shall be coupled with a coupling section,
mastic cement shall be applied between the
junction to make the joint water tight.
8.10.3.
Glazing
8.10.3.1.
Specifications described in para
7.2.9. shall apply. The glass panes shall
have square corners and straight edges.
The glass pane shall be so cut that it fits
slightly loose in the frames. In doors,
windows and clerestory windows of bath,
WC and lavatories frosted glass panes shall
be used which shall weigh not less than
2
.
10.00 kg/m for 4 mm thick glass
8.10.3.2.
Glazing shall be provided on the
outside of the frame unless otherwise
specified.
Putty of approved make
conforming to IS : 419 shall be used for fixing
glass panes. Putty shall first be applied
between glass panes and glazing bars.
Putty shall then be applied over the glass
pane, which shall stop 2 to 3 mm from the
sight line of the back rebate to enable the
painting to be done up to the sight line to
seal the edge of the putty to the glass. The
oozed out putty shall be cleaned and putty
cut to straight line. Quantity of putty shall not
be less than 185 gm/metre of glass
perimeter. Putty shall be painted within 2 to 3
weeks, after glazing is fixed to avoid its
cracking.
Note : Putty may be prepared by mixing one
part of white lead with three parts of finely
powdered chalk and then adding boiled
linseed oil to the mixture to form a stiff paste
and adding varnish to the paste at the rate of
1 litre of varnish to 18 kg of paste.
8.10.3.3.
Four glazing clips may be
provided per glass pane for a size larger
than 30 cm x 60 cm for all types. Where the
glass panes size exceed 80 cm x 200 cm, 6
glazing clips shall be used. In case of doors,
windows and ventilators without horizontal
glazing bars, the glazing clips may be
spaced according to the slots, in the vertical

members, provided the spacing does not
exceed 30 cm, otherwise the spacing shall
be 30 cm.
Note : Where large size glass panes are
required to be used or where the door or
window is located in heavily exposed
situation, holes for glazing clips have to be
drilled prior to fabrication as it cannot be
done at any later stage. Use of glazing clips
shall be specified while placing the order.
8.10.3.4.
Where specifically stipulated,
fixing of glass panes may be done with metal
or wooden beading instead of with putty.
Where beadings are proposed to be used,
the manufacturers shall be intimated in
advance to drill holes for hard screws.
Usually beads shall be fixed with screws
spaced not more than 10 cm from each
corner and the intermediate not more than
20 cm apart. When glass panes are fixed
with wooden or metal beading having mitred
joints, a thin layer of putty shall be applied
between glass panes and sash bars and also
between glass panes and the beading.
Where metal beading is specified extra
payment shall be made on this account
unless specified otherwise.
8.10.4.
Finishing
(a) All steel surfaces shall be thoroughly
cleaned of rust, scale and dirt. Where so
specified, the steel surfaces shall be treated
for rust proofing by the hot dip, zinc spray or
electro galvanizing process. A priming coat
of approved steel primer i.e. red oxide zinc
chrome primer conforming to IS: 2074 or as
specified shall be given. The fabricated steel
door, windows, ventilators and composite
units shall be inspected in the factory and
approved by the Engineer before priming
coat is applied.
(b) Final finishing coat shall be given to
the doors, windows and ventilators after they
are erected and fixed in final position. The
rate shall be exclusive of final finishing coats
but shall include the priming coat.
(c)
In case of galvanized doors, windows
and sashes, their surface shall be treated
with copper acetate solution or other
approved mordant solution to ensure proper
adherance of the paint, unless the
galvanised
surface
has
weathered
adequately at the time of final painting. Nonferrous parts and working parts such as
handles, stays, catches, handle pins, hinges
/ pins, etc shall not be painted. Treatment
with the mordant solution is not included in
the rate and shall be paid for separately.
8.10.5.
Fixing (Refer Figure 8.5)
8.10.5.1.
Steel, doors and windows shall
be so stacked as to keep them in true shape
without damage.
Doors, windows and
ventilators shall be fixed as described below:
8.10.5.2.
Metal doors, windows and
ventilators may be required to be fixed to
either masonry openings (including brick,
concrete, stone and marble) or timber
openings or steel work openings.
a)
Masonry
openings
Masonry
openings may either be rebated or flush and
in either case, they may have either external
rendering applied or be fair-faced (that is,
without external rendering). It is usual for
stone or marble masonry to be fair-faced.
b)
Timber openings Timber openings
are invariably rebated.
c)
Steelwork openings Steelwork
openings vary in detailed design but shall be
so designed that the outer frame of the door,
window or ventilator frame sections overlap a
steel surface either externally or internally.
Opening may be flush or rebated as shown
in the drawings. Where openings are flush
and with a rendered finish a clearance of
1.25 cm shall be provided between the steel
frame and opening (Figure 8.5). In case of
external masonry finish fair faced and with
rebated jambs, a minimum 1.25 cm
clearance between frame and opening shall
be provided (Figure 8.5). Opening in
steelwork shall be so designed that the outer
flange of the door, windows, or ventilator
frame section over-laps the steel surface by
10 mm (Figure 8.5).
Note: As mentioned in Para 8.10.1 (c) the
sizes of Indian Standard doors, windows and
ventilators, are designed for modular
opening 1.25 cm larger all round than the
doors, windows etc., This gap of 1.25 cm is
for the purpose of fixing of doors, windows
etc., In masonry openings, the gap is filled
up with mastic cement and plaster after the
door or windows is fixed in position. In the
case of steel or timber modular openings,
extra steel or timber fillets will be necessary
to cover this gap of 1.25 cm.
8.10.5.3.
Fixing in Masonry Openings
(a) Fixing with Lugs
(i)
Doors, windows and ventilators unit,
shall not be built in as the work proceeds
but opening shall be left out and frames fitted
afterwards so that the minimum specified
clearance between opening and unit frame is
left around. The size of the opening shall first
be checked and cleared of obstruction, if
any. The position of the unit and fixing holes
shall be marked on the jamb. Necessary

holes shall be made in the masonry and lugs
not less than 10 cm long 15 x 3 mm size
fixed in cement concrete blocks 15 x 10 x 10
cm size of 1:2:4mix (1 cement : 2 coarse
sand : 4 graded stone aggregate 20 mm
nominal size). The frames of units shall be
set in the opening by using wooden wedges
at the jamb, head and sill. Wedges shall
preferably be placed near the points where a
glazing bar meets the frames and be
plumbed in position.
(ii)
After it, the frame shall be fixed with
the lugs with 20 mm long and 6.3 mm dia
G.I. counter sunk machine screws and nuts.
In case of flush opening which are rendered
smooth, wedges shall be removed and gap
between unit and the jambs shall be filled
with cement mortar (see Figure 8.5)
(iii) In case of flush jamb with external fair
faced finish the gap between the opening
and frame shall be filled with mastic from
inside till it oozes out on external face. The
oozing mastic shall be cleaned and flush
pointed. The internal gap shall be filled with
rd
mastic to about 1/3 depth and the rest with
cement mortar (Figure 8.5).
(iv) In case of rebated jambs and jambs
finished fair faced externally, the mastic
shall be freely applied to the inside channel
of frame, jamb and sill, so as to ensure a
watertight joint. After the unit is firmly tied in
position surplus mastic shall be cleaned and
flush pointed, as shown in Figure 8.5.
(b) Fixing with screws and plugs
In R.C.C. work where lugs cannot be
embedded due to reinforcement bars etc.,
and in dressed stone and Marble surrounds,
rawl plugs or other approved metallic
fasteners may be fixed in proper position and
frame fixed to them with 60 mm galvanized
wood screws of designation 10.
8.10.5.4.
Fixing in Wood Works Opening:
Openings in wood work are normally rebated
and approved mastic or rubber linings shall
be applied to jambs, sill and channel before
fixing in position. The frame shall be set in
opening using wooden wedges as specified
in para 8.10.5.3. and fixed to the opening
with 60 mm galvanized wood screws of
designation 10. Extra timber fillets of hard
wood to match the adjoining work shall also
be provided around the frame to close the
extra gap between opening and frame (Refer
Figure 8.5)
8.10.5.5.
Fixing in Steel Work Opening:
Before placing the unit frame in position
approved mastic shall be applied as
specified in para 8.10.5.3. (a.iv) and a mild

steel or hard wood fillet shall be provided
around the frame to close the extra gap
between opening and frame. The unit shall
be fixed to the opening with fixing clips or
with nuts and bolts as shown in the drawings
or as directed by the Engineer. (Refer
Figure 8.5)
8.10.5.6.
Fixing of Composite Units: The
fixing procedure for composite units shall
generally be as described under paras
8.10.5.1. to 8.10.5.5 except that :
Where large units shall be formed by
coupling individual units together (with
coupling sections) the mullions and transoms
shall be bedded in mastic to ensure water
tightness. Mastic shall be applied liberally to
the channels of the outside frame sections
before assembly and after coupling. All
oozing out mastic shall be cut out neatly. If
there is a cross joint of mullion and
transome, the shorter coupling unit shall run
through unbroken. Mullions normally project
2.5cm at head and sill into the surround;
transomes also project 2.5cm into surround
and where appropriate they shall be cut.
8.10.5.7
Fixing of Aluminium frames
In case of Aluminium frames, the surfaces
shall be anchored in direct contact with the
surrounds and shall be protected with two
coats of alkali resistant paints, to avoid
chemical attack from the materials of
surround.
8.10.6.
Precautions
Care shall be taken that steel doors and
windows etc., are not deformed/damaged
during subsequent constructions. Particular
care shall be taken that scaffolding does not
rest on the steel door /window frames or
glazing bars.
All fittings and hinges (projecting hinges)
shall be protected, preferably with alkathene
sheets so that these may not be damaged
during execution of work.
8.10.7.
Measurements
The height and width shall be measured
correct to 1 mm.
The area shall be
calculated in square metre correct to two
places of decimal. The fixed, side hung and
top hung categories shall be measured
separately.
All composite units shall first be measured as
fixed. Extra shall then be added for side
hung, top hung and centre hung portions.
The measurements for extra for side hung,
centre hung and top hung windows shall be
taken from outside to outside of the
casement frames.
8.10.8.
Rate
for Supply and Fixing
by the Contractor
Rates shall include the cost of materials and
labour involved in all the operations
described above excluding two coats of
painting but including cost of glazing and
priming coat and the cost of projecting
hinges in case of side hung doors/windows,
plain hinges in case of top/bottom hung
windows/ventilators and pivots for centre
hung windows/ventilators.
Metal beading and other fittings such as peg
stays and casement window fasteners etc.
shall be enumerated and paid for separately.
Rate shall not include the cost of cement
concrete blocks if required for fixing of hold
fasts which will be paid for separately.
8.11.
T-IRON DOORS, WINDOWS
AND VENTILATOR FRAMES (Refer Figure
8.6)
8.11.1
General :
(a) T-iron doors, windows and ventilators
frames shall be manufactured from uniform
mild steel Tee section. The steel shall be of
the grade as provided in para 8.1.1. The
frames shall be got fabricated in a workshop
as approved by the Engineer.
(b) The sizes of doors, windows and
ventilator frames shall be as per drawing or
as decided by the Engineer MS tie bar of 10
mm dia shall be welded at bottom of the
frame. The size of doors, windows and
ventilators shall be calculated so as to allow
12.5 mm clearance on all sides to allow an
easy fitting in opening. The actual size of
doors, windows and ventilators shall not vary
by more than +2 mm than those shown in the
drawings.
The size of T section used for manufacture
of doors, windows and ventilators shall not
be less than those specified in IS:1038 (See
Figure 8.6), unless otherwise directed by the
Engineer.
8.11.2.
Fabrication
The frame shall be constructed using section
which has been cut to length andmitred. The
corners of the frames shall be butt welded to
form a true and right angle. All frames shall
be square and flat meeting the requirements
stated under para 8.10.2.1. The T section
shall be mitre joined and continuously butt
welded all along. The requirement of welded
joints shall be as specified under para
8.10.2.1.
8.11.3.
Fittings
Requisite number of holes shall be made in

the frame for fixing of fittings. Detailed
arrangements of fixing fittings shall be as
shown in Figure 8.6. All fittings shall be fillet
welded to T-iron frame all along the
periphery of contact.
i)
Butt hinges shall be fixed to the frame
as below:
M.S. flat of size 100 mmx 25 mm x 6 mm will
be welded with filet weld all along the
periphery of contact on the rear side of the
web of T-iron to receive the hinges.
Requisite number of holes shall be made in
T-iron frame and MS flat for fixing of hinges
with counter sunk steel screws as shown in
Figure 8.6.
(ii)
An alternate method of fixing butt
hinges can be adopted by fillet welding the
hinge to the T-iron frame on three sides. No
welding shall be done along the hinge pin to
allow free movement of butt hinges as shown
in Figure 8.6.
8.11.4.
Fixing
Fixing procedure for T-iron doors, windows
and ventilator frames in masonry opening
shall be as described in para 8.10.5. Fixing
arrangements of shutters to such frames is
shown in Figure 8.6.
8.11.5.
Measurements
T-iron doors, windows and ventilator frames
shall be measured in running metre, along
the centre line of the frame correct to a 1 mm
and weight calculated on the basis of
standard tables. No deduction or extra
payment shall be made for making holes and
making arrangements for fixing fittings
including packing wherever necessary. No
deduction will be made for not providing tie
bars in case of windows and ventilators.
8.11.6.
Rate
The rate includes cost of materials and
labour involved in all the operations
described above. It shall include the
necessary butt hinges and screws for fixing
the same with frame or as specified. But it
does not include the cost of other door and
ventilator fittings.
8.12.
PRESSED
STEEL
DOOR
FRAMES (Refer Figure 8.7)
8.12.1.
Material
Steel door frames shall be manufactured
from commercial mild steel sheet of 1.25 mm
thickness conforming to IS : 2062 and fittings
conforming to IS : 4351.
Steel door frames with or without fan light
shall be made in the profiles indicated in
Figure 8.7 and may be manufactured to suit

doors of either type, opening inwards or
outwards as directed by the Engineer.
8.12.2.
Construction
Each door frame shall consist of hinge jamb,
lock jamb, head and if required angle
threshold (Refer Figure 8.7). These shall be
welded or rigidly fixed together by
mechanical means.
Where no angle
threshold is required, temporary base tie
shall be screwed to the feet of frames in
order to form a rigid unit.
Where so
specified, base ties shall be of pressed mild
steel 1.25 mm thick adjustable to suit floor
thickness of 35 or 40 mm and removable, or
alternatively, threshold of mild steel angle of
section 50 x 25 mm minimum shall be
provided for external doors frames.
8.12.3.
Fabrication
The pressed steel door frames shall be got
fabricated in a workshop approved by the
Engineer.
8.12.3.1.
Fixing lugs (Figure 8.7). There
shall be three adjustable lugs with split end
tail to each jamb without fan light, and four
for jamb with fan light.
The head of the
fixing lug shall be one of the following
lengths:
(a) 95 mm long for use with profile A
(b) 120 mm long for use with profile B
(c) 160 mm long for use with profile C
The head shall be made from flat steel strip
25 mm wide and not less than 1.60 mm
thick. The tail of the lugs shall be 200 mm
long and shall be made of steel strip no less
than 40 mm wide and not less than 1 mm
thick.
8.12.3.2.
Hinges (Figure 8.7) 100 mm
mild steel but hinges shall be used. For door
frames 89 cm wide and under, three hinges
shall be rigidly fixed to one jamb and for
frames for door above 89 cm wide, four
hinges shall be rigidly fixed to one jamb, if it
is a single shutter. Where the height of the
door shutter exceeds 2.15 metres, one
additional hinge shall be provided for every
0.5 m or part thereof of the additional height.
In all cases the hinges shall be so fixed that
the distance from the inside of the head
rebate to the top of the upper hinge is 20 cm
and distance from top of upper hinge to
lower hinge is about 175 cm.
Hinges shall be made of steel 2.5 mm thick
with zinc coated removable pin of 6 mm
diameter. The space between the two leaves
of the hinge when closed shall be 3 mm and
the leaf that is not welded to the frame shall
have four counter sunk holes to take No. 10

wood screws.
8.12.3.3.
Mortar Guards: Mortar guards as
instructed by Engineer shall be provided.
These shall be welded to the frame at the
head of the frame for double shutter doors to
make provision for bolts.
8.12.3.4.
Lock-Strike Plate: There shall be
an adjustable lock-strike plate of steel
complete with mortar guard to make
provision for locks or latches complying with
the relevant Indian Standards. Lock-strike
plates shall be galvanized mild steel and
fixed at 95 cm from the head of the frame.
8.12.3.5.
Shock Absorbers: For side hung
door there shall not be less than three buffer
of rubber or other suitable material inserted
in holes in the rebate and one shall be
located on the centre line of the lock strike
plate and the other two at least 45 cm above
and below the centre line of the lock strike
plate. For double shutter doors, there shall
be two buffers of rubber or similar suitable
material inserted in holes in the rebate in the
lock jamb only at the head and spaced 15
cm at either side of the centre line of the
door.
8.12.4.
Finish
The surface of door frame shall be
thoroughly cleaned, free of rust, mill-scale
dirt, oil etc., either by mechanical means, for
example, sand or shot blasting or by
chemical means such as pickling. After pretreatment of the surface one coat of
approved primer i.e. red oxide zinc chrome
specified and two coats of paints as directed
by he Engineer shall be applied to the
exposed surface.
8.12.5.
Fixing
Frames shall be fixed up right in plumb. To
avoid sag or bow in width during fixing or
during construction phase, temporary struts
across the width preventing sides bulging
inwards may be provided. Wall shall be built
solid on each side and grouted at each
course to ensure solid contact with frame
leaving no voids behind the frame.
Three lugs shall be provided on each jamb
with spacing not more than 75 cm. The
temporary struts should not be removed till
the masonry behind the frame is set. In case
screwed base tie is provided, this should be
left in position till the flooring is laid when it
can be removed.
After pre-treatment of the surface, one coat
of steel primer and two coats of paint as
directed by the Engineer shall be applied to

the exposed surface.
8.12.6.
Measurements
The length shall be measured in running
metre correct to a cm along the centre line of
the frames.
8.12.7.
Rate
The rate shall include the cost of labour and
material involved in all the operations
described above including one coat of
approved steel primer but excluding two
coats of final paint.
8.13.
TUBULAR TRUSSES
8.13.1.
Structural Steel Tube - These
shall be of :
1.
Hot finished welded (HFW) type or
2.
Hot finished seamless (HFS) type, or
3.
Electric resistance or induction butt
welded (ERS), having carbon content less
than 0.03 percent, yield stress of 21.5
2
kg/mm (YST 22) type. Conforming to the
requirement of IS : 1161. The steel tubes
when analyzed in accordance with the
method specified in IS : 226 shall show not
more than 0.06 per cent sulphur, and not
more than 0.06 per cent phosphorous.
Tubes shall be designated by their nominal
bore. These shall be light, medium or heavy
as specified depending upon the wall
thickness. The standard sizes and weights of
tubes are listed in Annexure 8.4.
Tubes shall be clean finished and reasonably
free from scale. They shall be free from
cracks, surface flaws, laminations and other
defects. The ends shall be cut clean and
square with axis of tube, unless otherwise
specified. IS 806 deals with Code of Practice
for use of Steel Tubes for General Building
Construction and may be referred to for
details.
8.13.2.
Minimum thickness of Metals
Wall thickness of tubes used for construction
exposed to weather shall be not less than 4
mm and for construction not exposed to
weather it shall be not less than 3.2 mm.
Where structures are not readily accessible
for maintenance, the minimum thickness
shall be 5 mm.
8.13.3.
Fabrication
8.13.3.1.
The component parts of the
structure shall be assembled in such a
manner that they are neither twisted nor
otherwise damaged and be so prepared that
the specified cambers, if any, are
maintained. The tubular steel work shall be

painted with one coat of approved steel
primer after fabrication. All fabrication and
welding is to be done in an approved
workshop.
8.13.3.2.
Straightening:
All material
before
being
assembled
shall
be
straightened, if necessary, unless required to
be of curvilinear form and shall be free from
twist.
8.13.3.3.
Bolting:
Washers shall be
specially shaped where necessary, or other
means, used, to give the nuts and the heads
of bolts a satisfactory bearing. In all cases,
where the full area of the bolt is to be
developed, the threaded portion of the bolt
shall not be within the thickness of the parts
bolted together and washers of appropriate
thickness shall be provided to allow the nuts
to be completely tightened.
8.13.3.4.
Welding : Where welding is
adopted, it shall be as per IS : 816.
8.13.3.5.
Caps and Bases for columns:
The ends of all the tubes, for columns
transmitting loads through the ends, should
be true and square to the axis of the tubes
and should be provided with a cap or base
accurately fitted to the end of the tube and
screwed, welded or shrunk on. The cap or
base plate should be true and square to the
axis of the column.
8.13.3.6.
Sealing of Tubes: When the end
of a tube is not automatically sealed by virtue
of its connection by welding to another
member, the end shall be properly and
completely sealed. Before sealing, the inside
of the tubes should be made dry and free
from loose scale.
8.13.3.7.
Flattened Ends:
In tubular
construction the ends of tubes may be
flattened or otherwise formed to provide for
welded, riveted or bolted connections
provided that the methods adopted for such
flattening do not injure the material. The
change of sections shall be gradual.
8.13.4.
Hoisting and Erection
Tubular trusses shall be hoisted and erected
in position carefully, without damage to
themselves, other structures, equipment and
injury to workmen.
The method of hoisting and erection
proposed to be adopted shall be got
approved from the Engineer. The contractor
shall however be fully responsible for the
work being carried out in a safe and proper
manner without unduly stressing the various
members.
Proper equipment such as
derricks, lifting tackles, winches, ropes etc.,

shall be used.
8.13.5.
Measurements
The work as fixed in place shall be measured
in running metres correct to a centimetre and
their weights calculated on the basis of
standard tables correct to the nearest
kilogram unless otherwise specified.
Weight of cleats, brackets, packing pieces
bolts, nuts, washers, distance pieces,
separators diaphragm gussets (taking over
all square dimensions), fish plates etc., shall
be added to the weight of respective items
unless otherwise specified. No deduction
shall be made for skew cuts.
8.13.6.
Rate
materials involved in all the operations
described above including application of one
coat of approved steel primer i.e. red oxide
zinc chrome primer conforming to IS : 2074
or as specified.
8.14.
FAN CLAMPS (Figure 8.8)
8.14.1.
Types
The fan clamp shall be of the following types:
(a) Fan clamp to be fixed during the laying
of R.C.C. slab, shall be of type I, as shown in
Figure 8.8. This shall be made of 16 mm
M.S. bar bent to shape with its ends hooked.
The overall height of the clamps shall be
made to suit the depth of the slab.
(b) Fan clamp for beams shall be of type II
as shown in Figure 8.8. It shall be similar to
fan clamp, type I, except that its height shall
be greater depending on the depth of the
beam rib.
(c)
In case of low ceiling heights, circular
cast iron box for ceiling fan clamp, Type III
shall be fixed during the laying of R.C.C. slab
and shall be as shown in Figure 8.8. The
size of cast iron box shall be 140 mm internal
dia with 73 mm height. The thickness of cast
iron rim shall be 4.5 mm Bottom and top lids
shall be of 1.5 mm thick M.S. sheet with the
top surface hacked so as to ensure proper
bonding with the concrete. The lids shall be
screwed into the cast iron box by means of
3.3 mm dia round head screws one each at
the corners. The box can be of M.S. sheet
and the thickness of side walls can be
reduced to 3 mm without affecting inner dia
of the box. The fan clamp shall be made of
12 mm dia M.S. bar bent to shape with its
ends bent as per drawing.
8.14.2.
Fixing
Holes for inserting the fan clamps in the

positions shown in the drawing or as
instructed by the Engineer shall be made in
the shuttering after the latter has been fixed
in position. After steel reinforcement is tied,
fan clamps shall be fixed with their loops
truly vertical and at the correct depth from
the underside of the slab or beam. The
hooked arms and the loop shall be tied to the
reinforcement, either directly or through cut
pieces of M.S. bars with annealed steel wire
1.6 mm or 1.00 mm thick. The clamp shall
neither be disturbed out of position during
concreting nor shall it be bent out of shape
when shuttering of slabs or beams is
removed.
The exposed portion of loops of the clamp
shall be given two or more coats of paint,
including priming coat of approved steel
primer as ordered by the Engineer.
8.14.3.
Measurements
Clamps of type I and III shall be counted in
numbers. Fan clamps type II, shall be
counted and paid for under fan clamps type
I, but they shall in addition be paid for their
extra height as determined by the depth of
the beam.
8.14.4.
Rate
The rate per fan clamp shall include the cost
of labour and materials involved in all the
operations described above. In the case of
type 1 and III clamps, the rate shall apply
irrespective of the thickness of the slabs.
8.15.
MILD STEEL CLAMPS AND
RINGS FOR CHICKS
8.15.1.
M.S. Clamps
These shall be fabricated from M.S. flat iron
20 mm x 6 mm. One end shall be bent at
right angles for 25 cm length and other end
shall be tapered to a point. Total length of
clamp shall not be less than 15 cm.
These shall be built into the wall masonry,
while the work is in progress, so as to project
2.5 cm from the finished surface. These
shall be fixed in cement mortar. All clamps
shall be fixed in straight horizontal line as
shown in drawings or as specified by the
Engineer.
8.15.2.
M.S. Rings
These shall be made of 6 mm dia bars with
40 mm internal diameter. Their joint shall be
well formed or welded together. These shall
be provided with a 50 mm forked clamp of 10
x 3 mm M.S. flat iron. It shall be wide at the
fork end and pointed on the other end. These
shall be fixed in the masonry as specified in

para 8.15.1.
8.15.3.
Measurements
The M.S. clamps and rings shall be counted
in numbers.
8.15.4
Rate
and labour involved in all the operations
described above.
8.16.
M.S. BARS AND M.S. GRILLS
IN WOODEN OR STEEL FRAMES
8.16.1.
Fabrication
8.16.1.1
When M.S. round or square bars
are to be fixed in wooden or steel frames
these are cut into required length to form the
required pattern and then fixed as per
drawing. In the case of wooden frames the
length will be for fixing in the hole 5 cm deep
in one frame and right through and flush with
outer side of the frame.
8.16.1.2
are to be fixed to steel frames or in
combination with M.S. flats these are to be
cut to proper size welded to steel frames or
MS flats to form the required pattern. In
case of MS flats they should have counter
sunk holes to facilitate fixing them to wooden
frames with wood screws. Welding is to be
done in an approved workshop and not at
site.
8.16.1.3.
When the grill is to be fabricated
mainly with M.S. flats with or without M.S.
round or square bars, the flats of required
size are cut and bent to form the required
pattern and design as per drawing or as
directed by the Engineer. The cut and bent
flats and bars are then welded by fillet
welding all around the width of the flats or
circumference of bars which are joined. At
corners of flats proper mitred joint forming a
right angle shall be provided with welding for
full width. Welding is to be done in approved
workshop and not at site.
8.16.2.
Fixing
8.16.2.1.
are to be fixed to wooden frames the bars
shall be passed in to the wooden frame, from
the end having a through hole and fixed flush
with that end while at the other end it will be
5 cm deep in the hole drilled in the frame. In
case of steel frames, the bars will be welded
to the steel frame by fillet weld all along the
circumference of the bars in an approved
workshop and not at site.
8.16.2.2.
In case of grill of bars welded to
M.S. flat forming the required pattern, the
outer frame of M.S. flats shall be fixed to the

wooden frame with wood screws in the
counter sunk holes drilled in M.S. flats
ensuring that screws are driven with a screw
driver (not hammered) till the screws are
embedded fully inside flush with the M.S.
flats.
In case of fixing to steel frames, M.S. flats of
required pattern with or without M.S. round
or square bars, the method of fixing will be
similar to what is described above.
8.16.3. Welding : Any kind of welding at
site shall be permitted only under written
orders of the Engineer.
8.16.4. Measurements
The different types of M.S. grills as described
in para 8.16.1 will be measured separately
and paid for. The length of bars and flats
used in grills will be measured correct to a
cm and then weights calculated in kg by
using standard tables.The weight of
complete grill should be weighed at site and
minimum of the two will be taken for
payment.
8.16.5. Rate
and labour required for all the operations
described above. Grills of different types
mentioned in para 8.16.1 shall be paid for
separately.
8.17
ALUMINIUM WORK GENERAL
8.17.1 Materials
Aluminium alloy standard extruded sections
in a wide range of solid and hollow profiles
are used in the manufacture of frames,
shutters of doors / windows / ventilators,
supports for hand railings, curtain wall
facings, partitions, structural glazings and
similar other applications.
Tee / angle
sections are used for frame work of false
ceiling. The chemical composition and
mechanical properties of the extruded
sections
should
comply
with
the
requirements of IS 733, IS 1285 and IS 737.
Extruded sections should be procured only
from recognised ISO 9002 or equivalent
companies.
8.17.2 Anodising
The extrusions are anodised upto 30 Micron
in different colours like silver, champagne,
bronze and black and are to be tested to see
if the anodising conforms to the quality
standards laid down in Indian /British
Standard Specifications.
8.17.3
Aluminium Work for Doors,
Windows, Ventilators and Composite
Units
IS 1948 on Aluminium doors, windows and
ventilators and IS 1949 on Industrial
Alminium Windows were issued in 1961 and
not revised since then. Major manufacturers
of Aluminium products are however
manufacturing extruded sections etc to suit
the latest construction practice based on
British and International Standards. Hence it
may be difficult to procure Aluminium
sections to the sizes stipulated in IS codes
but the quality of extruded sections as
regards the materials and the anodising etc
is maintained by the manufacturers to satisfy
the requirements of IS Codes. Thus, for
procurement of Aluminium doors, windows,
ventilators etc a practical approach will be to
go in for sections manufactured by reputed
ISO 9002 or similar companies whether they
are strictly to sizes specified in IS Codes or
as specified in British or International Codes.
For joining procedure, providing fittings, lugs,
method of fixing etc. IS codes may be
followed in general with some modification to
suit the present day practice.
8.17.4 General
Specifications
and
Tolerances for Aluminium extrusions
Dimensions of the sections manufactured
should conform to the relevant IS, British or
other International Standards. Standard cut
length of sections is 3.66m. The tolerance in
cut length is + 5.00 mm upto 6 Metres length
of sections and + 7.00 mm for over 6 Metre
length sections. Actual weight per metre may
vary by + 10% of weight as specified
depending on functions like tolerance and
alloy.
8.18
ALUMINIUM DOORS
8.18.1 Extruded Sections
Dimensions and weight per Metre run of
extruded sections to be used for
manufacture of doors as laid down in IS
1948 are shown in FIGURE 8.9. Reputed
manufacturers produce various other types
of Extruded sections for use in doors.
8.18.2
Components of Doors and
Terminology
IS 1948 has specified the Terminology for
different components of the doors and the
same have been shown in FIGURE 8.4.
8.18.3
Sizes of fabricated doors
As per IS 1948, the sizes of doors specified
in the drawings (modular openings) should
be reduced by 1.25 cm on all four sides
during the manufacture of doors to enable

their fixing easily in the openings in the
Masonry. The module of opening in the
masonry is of 100mm. In practice while the
reduction in width of manufactured door by
2.50 cms as compared to the size of door
opening will result in availability of gap of
1.25 cm in each side, reduction in height by
2.50 cms will result in a gap of 2.5cms
between the bottom surface of RCC Lintel

and the gap of door to be filled by cement
plaster which is not desirable. This situation
arises due to discontinuation of the old
practice of providing a threshold at the
bottom of doors. With this proposal, the
following will be the desirable position for
some sizes of door openings.
Size of Door opening
Size of manufactured door
1200 mm x 2100mm
1175mm x 2087.5mm
800mm x 2100mm
775mm x 2087.5mm
600mm x 2100mm
575mm x 2087.5mm
The door verticals are to be embedded to a

length of 50mm in the floor and are not to be
counted while framing the door sizes or for
payment to the Contractor.
8.18.4
Use of symbols for Designating
Doors, Windows and Ventilators
Designated symbols and units as specified in
IS 1948 are as under:
a) Width : To be indicated by the number of
modules of 100mm each. Only the width of
opening is to be specified and not the width
of joinery of door.
b) Height :
Similar to width
c) Type : To be indicated by alphabets as
below.
C= Centre Hung Shuttles
F = Fixed Glass Panes
H = With Horizontal Glazing Bars
N = Without Horizontal Glazing Bars
S= Side Hung Shutters
T= Top Hung Shutters
Thus, Door Designated as 12 HS 21 means
Door to be fixed in opening 1200mm wide
and 2100mm high with Horizontal Glazing
bars and Side Hung Shutters. The size of
door will be 1175 mm wide and 2087.5mm
high as explained earlier. Doors and Side
lights are coupled with only 12 module high
window (opening 1200mm; Height of window
1175mm). In windows, since the question of
provision of threshold does not arise the
height of window will be 25mm, smaller than
height of opening with a gap of 12.5mm on
both top and bottom.
8.18.5
Glazing
Specifications described in Para 8.10.3.1 will
apply. Glass panes shall weigh atleast 7.5
kg/sqm and shall be free from flaws, specks
or bubbles. All panes shall have properly
squared corners and straight edges. The

glass panes shall be so cut that they are
slightly loose in the frames.
Glazing shall be provided on the outside of
the frames unless otherwise specified.
Fixing of glass panes shall be done with
Aluminium beading. Fabricator shall drill
appropriate holes for screws. Normally the
screws are spaced not more than 10 cms
from each corner and intermediate screws
are not more than 20 cms apart. When the
glass panes are fixed with Aluminium
beading having mitred joints, epoxy resin or
silicon sealant shall be applied between
glass panes and sash bars and also between
glass panes and the beading. The size of
glass panes will depend on the size of doors
/ windows / ventilators and the number of
horizontal glazing bars. All glass panes shall
be fixed within the Aluminium framing by use
of CP brass or stainless steel screws and the
joints sealed with epoxy resin or silicon
sealant to make the unit completely water
proof. Glazing or caulking compound around
the perimeter of glass shall not be permitted.
Fixed glass panes shall be supported by
setting blocks. For normal size glass panes,
glazing clips are not provided. For larger
size glass panes provisions in Para 8.10.3.3
will apply. The Aluminum anodised extruded
glazing beads or snap beading to be used
should be procured only from the
manufacturer
of
Aluminium
extruded
sections used for fabricating the doors /
windows/ ventilators.
8.18.6
Panelling
8.18.6.1
Different Types of Panels
The different types of panels that can be
used for aluminium doors shall be as follows:
i)
Ply Wood Panels :
Plywood boards used for panelling shall be

BWR type or grade as specified under Paras
7.2.2A & 7.2.2B. Each panel shall be a
single piece of 9mm thickness for two or
more panel construction and 12mm for single
panel
construction
unless
otherwise
specified.
ii)
Block Board Panels
(a) Block boards used for panelling of
shutters shall be Grade I (Exterior Grade)
bonded with BWP type synthetic resin
adhesive as specified under Para 7.2.6.
(b) Each panel shall be a single piece of
thickness 12mm unless otherwise specified.
iii)
Veneered Particle Board Panels /
Prelaminated Particle Board Panels
(a) Veneered
particle
board
/
Prelaminated particle board panels used for
panelling of shutters shall be exterior grade
bonded with BWR type synthetic resin as
specified in Para 7.2.3B & 7.2.3C.
(b) Each panel shall be a single piece of
thickness 12mm unless otherwise specified.
iv)
Fibre Board Panels / Prelaminated
Fibre Board Panels
Fibre boards / Prelaminated Fibre Board
used for panelling of shutters shall be
exterior grade bonded with BWP type
synthetic resin adhesive as specified under
Para 7.2.8A & 7.2.8B. Each panel shall be a
single panel of thickness 12mm unless
otherwise specified.
8.18.6.2
Thickness and Tolerance
i)
Plywood Panels : Plywood boards are
available in thickness ranging from 3 to
25mm. Tolerance in thickness shall be +
10% for boards upto and including 6mm and
+ 5% for boards above 6mm thickness.
ii)
Block Board Panels:
Block board
panels are available in thickness ranging
from 12 to 50mm. Tolerance in thickness
shall be + 5% for board upto and including
25mm thick and + 2.5% for boards above,
25mm thickness.
iii)
Veneered
Particle
Board
/
Prelaminated Particle Board: Veneered
particle boards are available in thickness
ranging from 6 to 50mm and Prelaminated
6mm to 45mm. Tolerance in thickness shall
be + 5%
iv)
Fibre Board Panels/Prelaminated Fibre
Board Panels: Fibre boards are available in
thickness ranging from 6 to 40mm.
Tolerance in thickness shall be + 0.3mm
8.18.6.3
Testing
The following stipulations will apply.
i)
Plywood : IS 304, IS 328, IS1328
ii)
Block Board : IS 3087
iii)
Veneered Particle Board : IS3097, IS :
12823 Prelaminated Particle Board
iv)
Fibre Board / Prelaminated : IS 12406,
IS 14587 Fibre Board
8.18.6.4
Fixing
The specified panels, cut to correct size with
minimum 12mm portion to be inserted in the
frame, shall be fixed firmly with CP brass or
stainless steel screws. The joints between
the panels and the members shall be sealed
with epoxy resin or silicon sealant to make
the unit water tight.
8.18.7
Aluminium Panels
Aluminium alloy sheet conforming to IS 737
and of thickness 1.25mm for use as kick
panels and of thickness as specified for other
general panels shall be procured from
reputed manufacturers. Fixing shall be done
as for other types of panels as indicated
above.
8.18.8
Fabrication
i)
Frames shall be square and flat. Both
the fixed and openable frames shall be
constructed of sections, which have been cut
to length, mitred and mechanically jointed at
the corners. Sub-dividing bars of units shall
be tenoned and rivetted into frames.
ii)
All frames shall have corners welded
to true right angles. For jointing hollow
sections flash butt welding, argon arc
welding or mechanical jointing by inserts
shall be used. Gas welding or brazing shall
not be done. Concealed screws shall be
used for joining the sub-units.
iii)
Doors shall be constructed with
sections as detailed in the drawing. Unless
stipulated otherwise, Hinges shall be nonprojecting and of heavy type. If specified or
directed by the Engineer floor springs,
closers, long grip handles and locks shall be
provided. In normal course standard lock
with lever handle shall be provided.
iv)
For double door, the first closing door
shall have a concealed aluminium alloy bolt
at top and bottom so constructed as not to
work loose or drop by its own weight.
v)
Standard projecting or butt hinges as
specified or as directed by the Engineer shall
be provided which shall be inserted into the
frames and riveted. For anodized work
suitable aluminium alloy pins shall be used.
The Engineer may permit the use of
mechanical jointing instead of welding.
vi)
Openable shutters shall be provided
with continuous neoprene weather strips.
Details of construction of aluminium doors

are shown in Figure 8.10A.
8.18.9
Tolerance
The sizes for doors shall not vary by more
than + 1.5mm.
8.18.10 Fittings
All fittings and fixtures shall be of high quality
and as shown in the drawings. The samples
of all fittings shall be got approved by the
Engineer before fixing. The general details
of fittings for doors as prescribed in IS:1948
are given below.
8.18.10.1 Hinges: Cast or extruded
aluminium alloy hinges for doors shall be of
same type as in the windows but of larger
size. Normally the hinges shall be of 50mm
projecting type as shown in Fig. 8.10B or
non projecting type as shown in Fig. 8.10C.
8.18.10.2 Handles : Handles for the doors
may be of the design as specified.
8.18.10.3 Locks : A suitable lock for doors
which can be operated from inside or outside
shall be provided. From point of view of
security, the lock which can be operated
from only one side is better and in case of
such locks, a bolt shall be provided to make
it impossible to operate from the other side.
8.18.10.4 Bolts
i)
In double shutter doors, the first
closing shutter shall have a concealed
aluminium alloy bolt at top and bottom as
shown in Fig. 8.10D.
It shall be so
constructed as not to work loose or drop by
its own weight.
ii)
Single and double shutter doors may
be provided with a three way bolting device
as shown in Fig.8.10E.
Where this is
provided in the case of double shutter door,
concealed aluminium bolts may not be
provided.
8.18.11
Positions
of
Holes
and
Number of Lugs per Units
Outer frames shall be provided with fixing
holes centrally in the web of the section in
the positions indicated in the Figure depicted
in IS Code but with lugs in the threshold of
the doors omitted. Instead the verticals of
doors are embedded to a length of 50mm in
the floor.
8.18.12
Fixing Aluminium Doors in
position
8.18.12.1 Fixing in opening of brick or
stone masonry
(a) Aluminium doors shall be stacked as
to keep them in true shape without damage.
Doors shall be fixed as described below:
b)
The sizes of Indian Standard doors are
designed for modular opening of larger width
by 1.25cm on both sides and larger height of
1.25cm only on top face.
In masonry
openings the gap is filled up with mastic
cement and plaster after the door is fixed in
position. In case of steel or timber modular
openings, extra steel or timber fillets will be
necessary to fill the gaps. Unlike in case of
wooden joinery where the wooden frame is
erected first and the masonry alround is
constructed later, in this case the size of the
opening is exactly same as in case of
wooden Joinery but the only difference is
that size of the door is reduced to enable
fixing of units easily.
(c)
Arrangement for fixing door frame with
steel lugs is shown in Figure 8.10F.
i) Slotted steel adjustable lugs (natural
finish) of size 100 x 16 x 3mm shall be as
shown in Figure 8.10G.
ii)
Any steel lug coming in contact with
aluminium should be either galvanised or
given a coat of bitumen paint.
iii)
Before the aluminium doors are fixed
in position, a thick shop coat of clear
transparent lacquer based on methylate or
cellulose shall be applied on aluminium
doors, windows etc to protect the surface
from wet cement during installation. The
lacquer coating shall be removed carefully
after plastering etc. complete to the
satisfaction of the Engineer without any extra
cost.
iv) The size of the opening shall first be
checked and cleared of obstruction if any.
The position of the fixing holes shall be
marked on the jamb. Necessary holes shall
be made in the masonry and lugs of size not
less than 100mm long and 15 x 3 mm size
fixed in cement concrete blocks of size 150 x
100 x 100 mm in 1:3:6 mix (1 cement: 3
coarse sand: 6 graded stone aggregate
20mm nominal size). The frame of units
after treating with lacquer coating shall be
set in opening by using wooden wedges at
jambs head. Wedges shall be preferably
placed near the points where glazing bar or
other members meet.
v)
The wedges should be fixed firmly only
when the doors / windows are kept in perfect
position and plumb. Later the frames should
be fixed with lugs with 20mm long and
6.3mm dia. GI counter sunk machine
screws and nuts. Only after ascertaining
that the doors are firmly fixed with lugs in the
opening, the wedges should be removed
very carefully and the gap should be filled
with mastic cement and plaster, taking
particular care to see that the plaster done

over jambs does not in any way abut the
front surface of aluminium door.
vi) After the gaps are filled with mastic
cement and plaster and the filling is finally
set, still if any crack / gap is noticed / pointed
out by the Engineer, the same should be
immediately filled with either epoxy resin or
silicon sealent.
8.18.12.2 Fixing on Concrete Surfaces:i)
In this case instead of using lugs to fix
the doors the same is fixed with wood
screws to the wooden plugs fixed in the
concrete surface.
ii)
As in earlier case the opening is
checked for size etc. The specified treatment
is given to the surfaces of aluminium doors
and the correct positions for fixing wooden
plugs marked on the jamb with respect to the
holes provided in the door for fixing screws.
iii)
On duly marked points on the jambs,
required size of hole shall be made in the
concrete and the wooden plug of teak wood
of specified size shall be fixed in the hole
with rich cement mortar. Units shall be
erected after plugs are duly set.
iv)
The door should be fixed to the
wooden plugs, with the help of galvanised
wood screws of size 45 designation.
v)
Later the 12.5mm wide gap between
the concrete surface and the aluminium unit
shall be filled neatly with mastic cement and
mortar. Alternatively if approved by the
Engineer instead of fixing the units on
wooden plugs, the same can be conveniently
and firmly fixed with rawl plugs using little
longer size screws of designation 10.
8.18.12.3 Fixing in Wood Work openings
Openings in wood-work are normally
rebated. Approved mastic or rubber lining
shall be applied to jambs, sill and channel
before fixing in position. The door shall be
set in frame using wooden wedges. The unit
shall be fixed using wooden screws
designation 10 of suitable length. Extra
timber fillets of specified type and size of
wood to match the adjoining work shall also
be provided around the frame to close the
1.25cm gap between the opening and the
aluminium unit.
8.18.12.4 Fixing in Steel-Work Opening
i)
Steel surfaces where the aluminium
units are to be fixed are cleaned and the
exact position of fixing the units is marked on
the surfaces with reference to the holes
already provided in the units.
ii)
Suitable holes are drilled in the steel
surfaces so that the clips / bolts used for
fixing units can be inserted.
iii)
The aluminium unit is then erected in
position and fixed temporarily with wooden
wedges. The frames are then fixed to the
steel surface using clips as shown in
Fig.8.10H or with suitable nuts and bolts as
directed by the Engineer.
iv)
Before the clips or the bolts are fully
tightened a suitable size mild steel or hard
wood fillet is introduced in the 1.25cm wide
gap after treating the surface of fillet and
jambs with approved mastic.
v)
The clips / bolts are then tightened and
simultaneously the wooden wedges provided
are removed. The gaps if any between the
units and steel surfaces shall be filled by
suitable / specified mastic or treated as
8.18.13
Measurements
8.18.13.1 Frame work
i) Only after ascertaining that the aluminium
doors fixed on site are manufactured by
reducing the width by 2.5cm and height by
1.25cm compared to the specified size of
openings in the drawings issued for
construction, the length of each extruded
section used for fabrication of the door shall
be measured correct to 1mm. In case the
sizes of doors that are manufactured,
happen to be the same as sizes specified in
the drawings, the theoretical dimensions
arrived by reducing the overall sizes may be
considered.
ii)
The weight of material used shall be
calculated on the basis of actual weight of
extruded sections used for fabrication and
shall be compared with the weights given in
the manufacturers catalogue, subject to the
condition that the variation in actual weight
should not exceed +10% compared to the
weights
specified
in
manufacturers
catalogue. Payment shall be made for the
actual weight of the extruded section. The
final weights shall be calculated in kg upto
two places of decimal.
8.18.13.2 Glazing: Length and width of
opening for glazing inserts shall be
measured correct to a cm and area for
payment shall be calculated in sqm nearest
to 0.01 sqm.
8.18.13.3 Panelling with Different Types of
Materials: Same as in Para 8.18.13.2 above.
8.18.13.4 Panelling with Aluminium Sheet:
The length and breadth of the panel inserts
shall be measured correct to a cm and the
area calculated to the nearest 0.01 sqm.
The weights of panel used shall be

calculated as under:i)
As per manufacturers catalogue
ii)
The actual weight of sample of sheet
used should be found out and weight of
panel actually used. (Actually calculated
weight shall be recorded subject to condition
that variation in actual weight shall not
exceed + 10% compared to the weight
specified in the manufacturers catalogue)
Least of above shall be considered for
payment.
The actual weight shall be calculated in kgs
to two places of decimal.
8.18.13.5 Fittings : All fittings for doors
except hinges and handles shall be
enumerated.
8.18.14
Rate
i)
The rate shall include the cost of
material and labour for all operations
described above except the cost of glazing
and panelling.
It shall include screws,
expansion hold fasteners, snap beading
including filling with necessary PVC /
neoprone felt, cleats etc. The rate does not
include the cost of fittings except the hinges
and handles.
ii)
The rate will include the cost for
providing aluminium alloy doors for the
openings of all shapes and sizes.
iii)
The cost of glazing, panelling and
additional fittings shall be paid under
separate item, as described herein.
8.198.19
ALUMINIUM
WINDOWS
OPENABLE TYPE
8.19.1
Aluminium Alloy Extruded
Sections Dimensions and weight per metre
run of extruded sections to be used for
manufacturing aluminium openable windows
as recommended in IS: 1948 are shown in
Fig. 8.11A. Reputed Manufacturers produce
various other types of Extruded Sections for
use in Windows.
8.19.2
Components of Windows and
Terminology
IS 1948 has specified the Terminology for
different components of Windows and the
same have been shown in Figure 8.4.
8.19.3
General Specifications on
tolerance for extruded sections. Refer
Para 8.17.4.
8.19.4
Sizes of Fabricated Windows
As per IS 1948 the sizes of windows
specified in the drawings should be reduced
in size by 1.25cm for all four sides of
openings while manufacturing the windows

so that fixing the windows in the openings
will be easy. Thus if the opening is of width
1000mm and height 900mm, the outer
dimensions of the fabricated windows shall
be of width 975mm and height 875 mm.
8.19.5
Use
of
symbols
for
Designating Windows - Please refer to
earlier Para 8.18.4.
8.19.6
Glazing - Please refer to earlier
Para 8.18.5.
8.19.7.1
Fabrication - Specifications
under earlier Para 8.18.8 (i) to (vi) will apply
in the case of windows also. Details of
Construction of Aluminium alloy windows in
accordance with IS 1948 are shown in
Figures 8.11B to 8.11E.
8.19.8
Tolerance: Same as prescribed
under Para 8.18.9.
8.19.9
Fittings
8.19.9.1
Side Hung Shutters
i)
For fixing aluminium alloy hinges, slots
shall be cut in the fixed frame and the hinges
inserted inside and may be rivetted to the
frame. The hinges shall normally be 67mm
wide projecting type as shown in Fig. 8.11F.
ii)
The hinges should be of specified
quality preferably with
ISI
mark
manufactured by reputed manufacturers.
iii)
The pins for hinges shall be stainless
steel of non-magnetic type or of aluminium
alloy HR 30. Irrespective of hinges being
anodised or not, the aluminium alloy pins
shall be anodised to a minimum film
thickness of 0.025mm and shall be sealed
with oil, wax or lanolin.
iv)
Non projecting type hinges as shown
in Fig. 8.11.G may also be used if specified
or permitted by the Engineer.
v)
Friction hinges: Working principle of
this is shown in Fig. 8.11.H. This may be
provided for side hung shutter aluminium
windows, in which case the windows need
not be provided with peg stays which are
normally used.
8.19.9.2
Handles For Side Hung
Shutters
i)
The handles shall be of cast aluminium
of specified quality, manufactured by reputed
manufacturers.
ii)
The handles shall be mounted on a
handle plate welded or rivetted to the
opening frame in such a way that it could be
fixed before the shutter is glazed.
iii)
The handle should have anodised
finish with minimum anodic film thickness of
0.015mm. The handle shall have a two point

nose which shall engage with an aluminium
striking plate on the fixed frame in a slightly
open position as well as in a fast position
shown in Fig. 8.11I.
iv)
The height of the handles in each type
of side hung shutters shall be fixed in
approximate position as shown in Fig. 8.11J.
8.19.9.3
Peg Stay
i)
The peg stay shall be either of cast
aluminium or folded from aluminium alloy
sheet. It shall be 300 mm long complete with
peg and levelling bracket as shown in Fig.
8.11K.
ii)
The stay shall have holes for keeping
the shutter open for three different positions.
The peg and
locking bracket shall be
rivetted or welded to the fixed frame.
iii)
The peg stays shall be provided only
when no friction hinges are provided for the
shutters.
8.19.10
Weather Bar: When a coupling
member is fitted over an external opening
shutter the coupling member should
incorporate an integrally extruded weather
bar as indicated in Figure 8.11A.
8.19.11
Position of Holes and Number
of Lugs per unit: The position of holes and
number of lugs to be provided for windows
of different sizes shall be in accordance with
IS: 1948.
8.19.12
Fixing Aluminium Windows in
Position: Same as explained for doors
under Para 8.18.12.
8.19.13
Measurements : As far as
applicable same, as prescribed under Para
8.18.13.
8.19.14
Rate
i)
Same as prescribed under Para
8.18.14.
ii)
Rate shall also include for windows in
openings of all shapes including circular,
segmental or other shapes and sizes.
8.208.20
ALUMINIUM
WINDOWS
SLIDING TYPE
8.20.1
Sections
IS 1948 has not laid down any guidelines for
manufacture of Extruded Sections. Reputed
manufacturers produce various types of
Extruded Sections for use in Sliding
Windows.
8.20.2
General
Specification
and
Tolerances for Aluminium Extrusions
Sections: Same as in Para 8.17.4.
8.20.3 Sizes of Windows for Fabrication:

Same as under Para 8.19.4.
8.20.4 Glazing: Same as under Para 8.18.5.
8.20.5 Fabrication
i)
Same as under Para 8.18.8 (i)
ii)
Same as under Para 8.18.8 (ii)
iii)
The different types of sliding windows
that are in use are:
1)
2/3 Track Sliding window
2)
3/4Track Sliding window
3)
20mm Sliding window
4)
100mm Sliding window
5)
123.45mm Sliding window
iv)
Use of these windows has increased in
the recent past as they do not occupy either
interior or exterior space while opening.
Windows are easy to operate.
v)
The sliding window of types described
under para (iii) above can be manufactured
in complete shape using aluminium alloy
extruded sections available in the market.
vi)
These windows do not require any
fittings except the self closing latch normally
fixed to the shutter while manufacturing and
the knob fixed on the sliding glass panes.
vii) The broad details of the construction of
a 3 track sliding window normally used are
shown under Fig.8.12. However, it should
be noted that the length and height of the
sliding window shall be reduced by 1.25cm
on all four sides from the prescribed length
and height of the opening for sliding window
shown in the drawing / item of work while
manufacturing the window.
8.20.6
Tolerance: Same as under Para
8.18.9.
8.20.7
Position of Holes and number
of Lugs per Unit :
In absence of any guidelines issued by IS
Code for sliding windows, details prescribed
for openable windows can be followed with
suitable modifications, wherever necessary.
8.20.8
Fixing
Sliding
Windows:
Same as explained under Para 8.18.12.
8.20.9
Measurements:
Same
as
prescribed under Para 8.18.13. Glazing
shall be same as prescribed under Para
8.18.13.2. However the cost of knob fixed in
the glass of sliding window glass need not be
paid separately.
8.20.10
Rate: Same as prescribed under
Para 8.18.14. Also the rate shall include the
cost of automatic closing latch provided in
the sliding window while manufacturing.
8.21
ALUMINIUM VENTILATORS
8.21.1
Sections
IS 1948 has laid down the dimensions and
weight per metre of Extruded Sections for
Ventilators. Details have been given in
Figure 8.13A. No extruded sections of other
sizes and shapes are being made by
Reputed Manufacturers.
However such
Extrusions as are being manufactured for
openable window can be used for making
ventilators.
8.21.2
Components of Ventilators
and Terminology IS 1948 has laid this
down as shown in Figure 8.4.
8.21.3
General Specifications and
tolerances for Aluminium Extruded
Sections : Same as in Para 8.17.4.
8.21.4 Sizes of Ventilators for Fabrication
: Same as under Para 8.19.4.
8.21.5 Symbols for Designating Windows
: Same as under Para 8.18.4.
8.21.6 Glazing : Same as under Para
8.18.5.
8.21.7 Fabrication :
i) As prescribed under Para 8.18.8(i) to (vi)
ii) Details of construction of aluminium alloy
ventilators as prescribed in IS : 1948 is
shown in Fig.8.13B
8.21.8
Tolerance : Same as under
Para 8.18.9.
8.21.9
Fittings
8.21.9.1
Hinges Top Hung Ventilators
i)
Top hung ventilators shall be provided
with aluminium hinges of recognised brand
or as specified. The hinges shall be either
cast or fabricated out of extruded sections
and shall be riveted to the fixed rail after
cutting a slot in it.
ii)
The ventilators shall also be provided
with a 300mm long peg stay
iii)
The peg stay shall have three holes in
different positions for opening the ventilator
and when closed shall hold the shutter tightly
by the locking bracket, which would be fixed
to the frame.
8.21.9.2
Cup Pivots Centre Hung
Ventilators
i)
The centre hung ventilators shall be
hung on two pairs of cup pivots as shown in
Fig. 8.13C or on brass or bronze cup pivots
which should be either chromium or
cadmium plated and riveted to the inner and
outer frames of the ventilator to permit the
ventilator to swing through an angle

o
approximately 85
ii)
The opening portion of the ventilator
shall be so balanced that it remains open at
any desired angle under normal weather
conditions.
8.21.9.3
Spring Catch Centre Hung
Ventilator
i)
The spring catch shall be of specified
make and type conforming to relevant IS
Specifications and shall be made of either
chromium plated or cadmium plated.
ii)
The spring catch shall be fitted in the
centre of the top bar of the ventilator, for its
operation.
This spring catch shall be
secured (preferably screwed or rivetted) to
the frame and shall close into the aluminium
catch plate rivetted or welded to the outside
of the outer ventilator frame bar.
8.21.9.4
Cord
Eye
and
pulley
arrangement Centre Hung Ventilator
i)
Cord pulley wheel shall be of
aluminium or cadmium plated brass in an
aluminium bracket.
ii)
This shall be fitted to the sill of the
ventilator, with aluminium or galvanised or
cadmium plated steel screws or alternatively,
welded together with an aluminium cord eye
rivetted or welded to the bottom inner frame
bar of the ventilator in a position
corresponding to that of pulley.
8.21.10
of Lugs per Unit : The position of holes and
the number of lugs should be provided for
the ventilators of different sizes in
conformation to relevant IS Code.
8.21.11
Fixing Aluminium Ventilators
in position : Same as prescribed for doors
under Para 8.8.12.
8.21.12 Measurements : Same as explained
under Para 8.18.3. Glazing shall be same as
explained under Para 8.18.13.2
8.21.13
Rate : Same as prescribed
under Para 8.18.14.
8.228.22
ALUMINIUM
COMPOSITE
UNITS
8.22.1
Sections
IS 1948 has laid down the dimensions and
weight per metre of Extruded Sections for
doors, openable windows and ventilators. In
addition, reputed manufacturers fabricate
other sizes and shapes of extensions which
can be used. The extruded section specially
indicated for composite units and IS 1948

are shown in Figure 8.14A.
8.22.2
Components and Terminology
: IS 1948 has laid down the same as shown
in Figure 8.4.
8.22.3
General Specification and
sections: Same as under Para 8.17.4.
8.22.4
Sizes of Doors, Windows and
Ventilators of Composite Unit for
Fabrication
i)
Fixing sizes of composite unit for
fabrication is a most complex issue as not
only the three items like door, window and
ventilator are involved but also the width of
extruded sections like mullion and transome
have also to be accounted for, while deciding
the actual fabrication width and height of
members and ultimately the composite unit
after accounting for the necessary deduction
of 1.25 cms from specified size of composite
unit before proceeding with the fabrication of
the different components of the composite
unit.
ii)
Consider a 12 module (1200mm) wide
and 21 module (2100mm) high door is
coupled on its top with a 12 module
(1200mm) wide and 6 module (600mm) high
ventilator.
iii)
This unit i.e. the door coupled with
ventilator on top is again coupled by its side
with a window 15 module (1500mm) wide
and 12 module (1200mm) high which is also
coupled on top with a ventilator of 15 module
(1500mm) width and 6 module (600mm)
height and the shape will be as shown in
Figure 8.14B.
8.22.5
Symbols
for
Designating
Composite Units: Same as under Para
8.18.4.
IS 1948 has recommended the method of
designating the composite unit consisting of
door, window and ventilator as described
below:
(1) A 12 module wide and 21 module high
horizontally glazed side hung door coupled
on its two sides with two side hung
horizontally glazed windows 6 module wide
and 12 module high is designated by the
symbol 6HS 12/12HS21/6HS12.
(2) Two 10 module wide and 12 module
high horizontally glazed side hung windows
coupled side by side with two fixed glass
pane ventilators at top each 10 module wide
and 6 module high is designated by the
symbol.
10 HF6/10HF6
10HS12/10HS12
8.22.6
Glazing : Same as under Para
8.18.5.
8.22.7
Panelling : Same as under
Para 8.18.6.
8.22.8
Aluminium Panel : Same as
under Para 8.18.7.
8.22.9 Fabrication:
i)
Same as prescribed under Para 8.18.8
for doors, Para 8.19.7 for windows and Para
8.21.7 for ventilators.
In addition the
following requirements for composite units
shall be noted.
ii)
The doors shall be coupled with
windows or side lights with extruded
aluminium million coupling bars and
transome as shown in the drawings or as
iii)
The coupling member should conform
to the dimensions shown in Figure 8.14C or
8.14D.
iv)
Where a coupling member/ transome
is fitted over an external opening shutter, the
coupling should incorporate an integrally
extruded weather bar as shown in Figure
8.11A.
8.22.10
Tolerance :
Same
as
under Para 8.18.9.
8.22.11
Fittings : Same as prescribed
for doors, windows and ventilators.
8.22.12
of Lugs per unit
i)
The position and number of lugs to be
provided for a composite unit have been
shown in IS 1948 and the same can be
followed with certain modifications wherever
needed.
ii)
In case the lugs are not to be used and
only holes are to be drilled the same shall be
drilled in the position of lugs as shown in the
Drawing in IS 1948.
8.22.13
Fixing Aluminium Composite
Unit in Position: Same as prescribed under
Para 8.18.12
8.22.14
Measurements :
Same as
under Para 8.18.13
8.22.15
Rate
i)
Same as in Para 8.18.14 and in (ii) of
Para 8.19.14.
ii)
The rate does not include the cost of
mullion bar or transome / weather bar and
the same shall be paid separately under a

separate item in running metres.
8.238.23
FLOOR
SPRING
(HYDRAULICALLY REGULATED)
8.23.1 Type and Size Typical details are
given in Figure 8.15. It shall be as per IS
6315.
8.23.28.23.2
Construction
and
Operational Details
i)
The floor springs shall be suitable for
fixing to the doors weighing upto 125 kg
without use of additional door units.
ii)
The floor spring shall operate smoothly
and easily without undue delay during the
opening and closing operations.
iii)
The oil check shall work satisfactorily
o
o
at all temperatures between 49 and (-) 10
without requiring any other change except by
adjustment of the capstan nut.
iv)
The speed of the closing door shall be
adjustable by means of a suitable controlling
device. Tension of the spring shall be
increased or decreased by turning the
capstan nuts clock-wise or anti-clockwise.
For exceptionally low temperature the
adjustment in the speed could be made by
change in the grade of oil.
v)
The shoe shall be fitted to the
governing pivot of the floor spring by a
square profile so that it stands horizontally
parallel with the top cover plate of the floor
spring. Provisions shall be made in the shoe
for adjusting the door leaf to the final closing
position by turning a screw.
vi)
When the door is opened at right
angle, the door shall stand open till it is
pushed to close.
8.23.3
Performance of Floor Spring
i)
The closing time of the floor spring
shall be easily adjustable between 3 and 20
seconds for which a suitable device to adjust
the speed shall be provided.
ii)
After being fitted in position the door
o
o
leaf shall be opened through 90 plus 5 and
released. When opened to an angle less
than a right angle the door shall swing back
automatically.
8.23.3
Workmanship -The floor spring
shall be free from all mechanical defects,
sharp edges and other surface defects.
8.23.4
Quality Assurance - The floor
spring should be with ISI mark for quality
assurance.
8.23.6
Fixing
Suitable recess of the required size shall be

cut in floor and the floor spring with all its
components viz. cover plate, outer box with
slide plate etc. shall be embedded in floor.
8.23.6
Measurements - =The floor
spring shall be measured in numbers.
8.23.8
Rate
The Rate shall include the cost of labour and
material involved in all the operations
described above and making good the floor.
8.24
ANODIZED
ALUMINIUM
ALLOY GRID FOR FALSE CEILING
8.24.1
Material and Anodizing - Same
as under Para 8.17.1 and 8.17.2
8.24.2
Aluminium Alloy equal /
unequal angles and tees prescribed as
per IS Standards.
IS 3908 and IS 3909 may be referred to for
details. Reputed manufacturers manufacture
other sizes of angles as required.
8.24.3
Fabrication and Fixing in
Position
i)
The interlocking aluminium alloy grid
shall consist of aluminium main Tee
runners of size 25 x 40 mm and 2.10mm
thick or as specified / directed, spaced
1200mm c/c and cross Tee of size 24 x 24
mm
and
2.10
mm
thick
or
as
specified/directed, 1200mm long spaced
between the main Tee at 600 mm c/c to
form a grid of 1200 x 600 mm. Again a
secondary cross Tee of length 600 mm and
size 24 x 24 mm and 2.10 mm thickness or
as specified / directed to be interlocked of
the centre of 1200 x 600 mm panel to form a
grid of 600 x 600 mm.
ii)
Main Tee runners are to be
suspended from ceiling with M.S. level
adjusting hangers.
iii)
The perimeter support on wall shall
consist of aluminium angle of size 25 x 25
mm and 1.60 mm thickness or as
specified/directed fixed firmly to the walls
with the help of rawl plugs spaced at 230 mm
c/c and tightened with 25 mm long cadmium
plated screws or as directed.
8.24.4
Measurements
The aluminium Tee or Angle iron sections
when fixed in position shall be measured
correct to 1mm.
The weight per metre length of used T
angle sections shall be ascertained by
weighing the sample length and the weight
thus worked out shall be compared with the
weight per metre prescribed by the
manufacturer. However payment shall be

made for only the actual weight worked out
after ascertaining the weight of sample
piece, subject to the condition that the weight
per metre ascertained is within the tolerance
limit of + 10% of the weight of section
prescribed in the manufacturers catalogue.
8.24.5
Rate
The rate includes the cost of materials and
labour involved in all operations described
above except the M.S. Level adjusting
hangers and its fixing arrangement which
shall be measured and paid separately as
described under Para 8.25.
8.25
PROVIDING
AND
FIXING
LEVEL ADJUSTING HANGERS 6 MM DIA
M.S. ROD (UPTO 1200 MM LENGTH)
8.25.1
Materials: Mild steel bars shall
conform to the relevant IS specifications.
These shall be fabricated from MS bar of 6
mm diameter.
8.25.2
Fixing
Necessary holes for expansion hold
fasteners as per the architectural drawing
shall be made in slab with drilling machine.
MS angle 40 x 40 x 5 mm and 40 mm long
shall be fixed with hold fasteners 12.5 mm
dia and 40 mm long. MS angle and steel rod
should be given a priming coal of zinc
chromate yellow primer or any other primer
as stipulated, complete as per direction of
the Engineer.
8.25.3
Measurements - The level
adjusting hanger rods shall be measured in
Kg.
8.25.4
Rate
material involved in all the operation
described above.
8.26
PROVIDING
AND
FIXING
MACHINE
MOULDED
ANODISED
ALUMINIUM
COVERING
OVER
EXPANSION JOINTS
8.26.1
General : Specifications and
material shall conform to requirements as
laid in paras 8.17.1 & 8.17.2. The aluminium
sheet shall be of approved make and
conforming to specification laid in IS: 737.
Aluminium sheet of required width and
thickness shall be made out of wider sheet
duly machine cut. Machine moulded covering
may be:
(i)
170 mm wide anodised aluminium
sheet 2.5 mm thick.
(ii)
210 mm wide anodised aluminium
sheet 2.5 mm thick.
(iii) or of any other width/thickness
specified in the description of item.
8.26.2
Fixing
Aluminium sheet shall be machine-holed at
required spacing. Staggered holes in the
receiving surface will be done with drilling
machine and expandable plastic sleeve be
provided in the holes. Aluminium sheet shall
be fixed with cadmium plated 4 mm dia 30
mm long full threaded screws with 2 mm
thick anodised aluminium washer complete
as per the direction of as Engineer.
Anodising on the aluminium sheet and
washer to be 15 micron thick.
8.26.3
Measurements
The length of aluminium sheet covering shall
be measured in running metre correct to 1
cm. Payment shall be made for least of
weight calculated on the basis of unit weight:
(i)
Unit weight specified in manufacturer
catalogue.
(ii)
Actual weight per sqm.
8.26.4
Rate
Rate includes the cost of material land labour
involved in all the operations described
above.
It shall include screws, plastic
sleeves etc. complete.
8.27
ALUMINIUM CURTAIN WALL
SYSTEM /CLADDING
8.27.1
General
(1) The type of work is not an ordinary job
which can be executed by the Contractors
doing the general building works but this is a
specialised job.
(2) These structures are designed for the
following effects:
(a) Permanent
Deformation,
thermal
expansion
(b) Wind and seismic load
(c)
Air and water infiltration or leakage
(d) Lateral deflection per floor height
(3) Normally for executing such works, the
design of the system is prepared by the
specialized firm and then the same is
submitted to the department/architect for
approval and only after detailed scrutiny and
checking design calculations and drawings,
the design is accepted and the firm is asked
to take up the job.
8.27.2
Specification for Materials
used for Curtain Wall
(1) Glazing : As specified in the

description of the item or as described under
Para 8.18.5.
(2) Framing system :
Aluminium
anodized extruded sections manufactured by
reputed manufacturers for all types of
members like brackets, mullions, transome
etc.
(3) Sealant : As specified in the item or
silicon sealant.
(4) Insulation : 50 mm thick glass wool of
minimum density48 kg/cum sandwiched with
black polythene sheet 100 micron on one
side and aluminium foil of 100 micron on the
other side or as specified by manufacturer at
spandrel area. The surface after fixing
insulation shall be plain without any
distortion.
(5) Heat Reflective : As specified. Brown
or Grey Colour of any Toughened Glass
shade approved by the Engineer.
8.27.3
Sections Manufactured and supplied by
reputed companies.
In absence of specific extruded sections
available conforming to BIS Specifications,
extruded sections manufactured by reputed
companies are used on works.
8.27.4
Main Components
Main Components of the Curtain Wall
System are shown in Figure 8.16 A
8.27.5
Produced by manufacturers - Same as
under Para 8.17.4
8.27.6
Glazing - Same as under Para
8.18.5
8.27.7
Panelling - Same as under
Paras 8.18.6 and 8.18.7
8.27.8
Scope of Work
8.27.8.1
Preliminary Requirements
(i)
The Contractor shall design, test,
fabricate, deliver, install and guarantee all
construction necessary to provide a
complete curtain wall system for the
proposed building, all in conformity with the
drawings as shown.
(ii) Specification
and
all
relevant
construction regulations including providing
any measures that may be required to that
end, not withstanding any omissions or
inadequacies of the drawings.
(iii) The curtain wall system shall also
include the following activities/ elements.
(a) Metal frames, glass glazing, spandrels,

ventilators, finish hardware, copings, metal
closure, windows etc.
(b) All anchors attachments, reinforcement
and steel reinforcing for the systems required
for the complete installations.
(c)
All thermal insulation associated with
the system.
(d) All fire protection associated with the
system.
(e) All copings and closure and metal
cladding to complete the system.
(f)
All sealing and flushing including
sealing at junctions with other trades to
achieve complete water tightness in the
system.
(g) Isolation of dissimilar metals and
moving parts.
(h) Anticorrosive treatment on all metals
used in the system
(i)
Polyester powder coating of aluminium
sections.
(iv) The Contractor shall also be
responsible for providing the following:
(a) Engineering proposal, shop drawings,
engineering data and structural calculations
in connection with the design of the curtain
wall system.
(b) Mock-ups, samples and test units.
(c)
Performance testing of the curtain wall
framing and glazing assembly.
(d) Co-ordination with the work of other
trades.
(e) Insulation with glass wool 48 kg/cum at
spandrels area.
(f)
Protection.
(g) All final exterior and interior cleaning
and finishing of the curtain wall system.
(h) As built record drawings and
photographs.
(i)
Guarantees and warranties.
(j)
All hoisting, scaffolding, staging and
temporary services.
(k)
Conceptualising and design of a
suitable maintenance system for curtain
glazing.
(v) The water tightness and structural
stability of the whole curtain wall system are
prime responsibility of the contractor. Any
defect or leakage found within the guarantee
period shall be sealed and made good all at
the risk and cost of the contractor.
(vi) The curtain wall system shall be
designed to provide for expansion and
contraction of components which will be

caused by an ambient temperature range
without causing buckling, stress on glass,
failure of joint sealants, undue stress on
structural elements or other detrimental
effects, specific details should be designed
to accommodate thermal and building
movements.
8.27.8.2
Design Requirements
(i)
Curtain wall shall comply with all
government codes and regulations, building
bye-laws, if any.
(ii)
All curtain walling, individual aluminium
and glass components and all completed
work shall be designed and erected to
comply with the requirements given in (iii)
below:
(iii) (a) Basic Requirement : The basic
design and architectural requirements shall
consist of the size of window, net glass area,
ventilator, configuration of widows and
spandrels to be retained.
However the
contractor may propose alternatives on the
construction details provided that all basic
functional and architectural requirements are
fulfilled.
(b) Quality Consideration and other
Activities
The contractor while submitting the detailed
design calculations should submit the
following information on the quality of
materials to be used and other aspects as
detailed below:(1) Metal quality, finishes and thickness
(2) Glass quality, coating and thickness
and manufacturers brand names.
(3) Aluminium extruded sections including
mullions and transomes together with
structural calculations and manufacturers
brand name and also the name of agency
proposed for fabrication work.
(4) Arrangement
and
jointing
of
components.
(5) Field connections especially mullion to
mullion and transome to mullion.
(6) Fixing and anchorage system of typical
wall unit together with structural calculations.
(7) Drainage system and provision in
respect of water leakage in the curtain wall
system.
(8) Provisions for thermal movements
(9) Sealant and sealing methods.
(10) Glazing Method.
(11) Wind load and seismic load and any
other specific load considered in the design.
Design concept over lightning protection linkup system of the curtain wall for connection
and incorporation into the lightning conductor
system of the building (Lightning conductor
system of the building to be done by any
other agency).
The
maximum
permissible
structural
tolerances of the building that the system
has been designed to accommodate in case
these tolerances exceed those specified in
the specification.
(c) Tolerances : Any parts of the curtain
wall, when completed, shall be within the
following tolerances :
(1) Deviation from plumb, level or
dimensioned angle must not exceed 3 mm
per 3.5 m length of any member, or 6 mm in
any total run in any line.
(2) Deviation from theoretical position on
plan or elevation, including deviation from
plumb, level or dimensioned angle must not
exceed 9 mm total at any location.
(3) Change in deviation must not exceed 3
mm for any 3.5 m run in any direction.
(d) Samples : The contractor shall also
submit samples ofaluminium extruded
sections, mullion and transome sections in
lengths of 300 mm with the same finish and
workmanship as per the tender proposals
and 300 mm x 300 mm samples of glass
(samples to include exposed screws and
other exposed securing devices if any).
(e) Ancillary Requirements to be fulfilled
by the Contractor
The contractor/sub-contractor shall submit a
maintenance manual for the curtain wall
system covering of all metal parts, glass and
finish etc.
During detailed design scrutiny and also
during the actual execution of the work, any
additions and extra provisions that will have
to be made as per theoretical requirements
or site conditions shall be implemented and
executed by the contractor at his own cost,
without claiming any thing extra under any
circumstances.
8.27.9
Execution of Work
8.27.9.1
Performance Testing
To be done at the cost of the Contractor with
copies of Test Reports to besubmitted to the
Engineer.
(i)
Mock-up units shall be constructed by
the Contractor and tested to determine the
structural stability as well as air and water
infiltration or leakage at glazing beads and all
other joints designed into the face of the
building.
(ii)
Tests of wind pressure, lateral
deflection per floor height and water
tightness shall be conducted on the mock-up
limit in a recognized Testing Laboratory to
prove the satisfactory functioning of the
curtain wall system. Record of Tests and of
Drawings of the System should be made
available to the Railway by the Testing
Laboratory.
8.27.9.2
Fabrication and Erection
The Grid for the Curtain Walls System shall
be fabricated as per approved drawing.
Care should be taken to see that any gap
between its frame and support and the frame
itself is sealed with Silicon Sealants. Finish
of grid frame shall be eitherandoised, organic
coating, baked enamel finish or as specified
in the item of work. Care should be taken to
see during erections that the curtain walls
system is not deformed or damaged.
A typical curtain wall system with the position
of main members like mullions, transome
glazing etc is shown to Figure 8.16 B.
8.27.10
Performance Guarantee
Normally, performance guaranty for a period
of 5 years should be insisted upon to cover
the cost of rectification of defects noticed
during the guarantee period.
8.27.11
Measurements
(i)
The breadth and height of the finished
work including the openable window shall be
measured in metres and net quantity for
payment calculated in Sqm up to two places
of decimal.
(ii)
The area to be considered for the
payment shall be the net area of the exterior
face of the curtain wall as fixed including the
operable windows if any as part of the
curtain wall system.
8.27.12
Rate
The rate shall includes the cost of all
operations described above including the
cost of materials labour, design, shop
drawings, erection and testing of mock-up
test unit,
fabrication, erection, finishing
scaffolding and undertaking of performance
guarantee.
8.27.13 Cladding Material (Aluminium
Composite Panel)
Product Composition of shall be as below :
8.27.13.1 Aluminium Composite Panel
shall be of total thickness of 4mm (Tolerance
of +/- 0.2mm); comprising of aluminium skin
of 0.5mm with Kynar 500 PVdF (Poly Vinyl
Di Flouride) paint + 3.0mm LDPE based core
material + 0.5mm aluminium skin with
service coat; bonded together by calendaring
process.
ACP of total thickness 3mm (Tolerance of +/0.2mm) will comprise of aluminium skin of
0.3mm with Kynar 500 PVdF (Poly Vinyl Di
Flouride) paint + 2.4mm LDPE based core
material + 0.3mm aluminium skin with
service coat; bonded together by calendaring
process.
8.27.13.2 Aluminium Skins outer &
inner, should conform to 3003 grade, having
a Temper of H-16, sourced from standard
aluminium producers, adopting Direct
Casting Method, resulting in better bonding
of aluminium molecules.
2
(i)
Tensile Strength of Skin 165 N/mm
(minimum)
(ii)
Thickness of Skin : 0.5mm (+/0.03mm)
8.27.13.3 LDPE Core Non-toxic low
density Polyethylene core 3mm thick, having
3
3
a Density Range of 920 kg/m to 960 kg/m ;
Raw material sourced from IPCL 040 Grade.
8.27.13.4 Thickness of self adhesive
Peel-off/Protective Foil 80 microns,
tested to withstand at least 45 days exposure
to local weather conditions without loosing
original peel off characteristics or causing
stain/damages on coated surface of
Aluminium Composite Panel.
8.27.13.5 Coating Properties (As per

AAMA 2605/620)
Coil Coating Method 3 Steel Roller Based;
simultaneous Two Coat Two Bake / Three
Coat - Three Bake; depending on
color/shade or RAL/Pantone no.
Coating Thickness (a) For Exterior Applications (PVdF) :
(i)
Front Coil : 25 - 30 in PVdF
Including Primer (PVdF Paint : 1820
microns + Primer : 6-8 microns)
(ii)
Back Coil : 4 - 7 Polyester Coating
(b) For Interior Applications (Modified
Polyester/Polyester) :
(i)
Front Coil : 15 - 18 in Polyester
Coating
(ii)
Back Coil : 4 - 7 Polyester Coating
8.27.13.6 Tensile Strength of Aluminium
Skin
2
(a) AA 3003 series - 165 N/mm (minimum)
2
(b) AA 3105 series - 185 N/mm (minimum)
8.27.13.7 Density of LDPE-CORE :
3
3
920Kg/m - 980 Kg/m (NonToxic Grade
Polyethylene)
8.27.13.8 Adhesive Film - Made from
Ethylene Co Polymer
8.27.13.9 Color Choice - Color choice shall
be as per selection of the Railways
8.27.13.10 Product Quality & Warranty
(i)
PVdF coated panels to carry a 10
years warranty on weather durability,
UV color fading, corrosion, chalking,
etc. Panels shall be manufactured and
tested extensively as per AAMA
Standards.
(ii)
Aluminium Coil is sourced from
standard manufacturer as per IS
737:1986.
(iii) AA 3003 is IS:31000 and AA 3105 is
IS:51300
8.28
STRUCTURAL GLAZING
8.28.1
Specification for materials to be
used - Para 8.27.2 will apply
8.28.2
Aluminium
Alloy
Extruded
Sections
BIS Codes have not laid down the standards.
Reputed companies manufacture extruded
sections of different types and unit weights.
8.28.3
Tolerances for Aluminium Extrusions Same as under Para 8.17.4
8.28.4
Glazing - Same as under Para
8.18.5
8.28.5
Scope of Work - Same as
under Para 8.27.8
8.28.6
Execution of Work
(i)
Same as under Para 8.27.9
(ii)
Though both the systems i.e. curtain
wall system and structural glazing are very
much similar, still the type and shape of
aluminium extruded sections that are used in
this case are totally different.
(iii) Another noted difference between the
two systems is that in elevation the structural
glazing looks as total glass surface without
any beading visible externally, whereas in
case of curtain wall system the cover plate
used on the surface is clearly visible in
elevation.
(iv) A large quantity of sealant has to be
used for the execution of the work of
structural glazing with the result the cost per
sqm. of structural glazing works out to be
much on higher side.
(v)
There is also a slight difference in the
actual fabrication of the two systems though
quantity of materials required for execution in
both the cases is same except the quantity of
sealant.
(vi) A typical structural glazing system with
the position of main members like mullion,
transome, glazing etc., are shown in Fig.
8.17.
8.28.7
Performance
Guarantee
Same as under Para 8.27.10
8.28.8
Measurements - Same as
under Para 8.27.11
8.28.9
Rate - Same as under Para
8.27.12
8.29
ALUMINIUM
STAIRCASE
RAILINGS AND BALUSTER
8.29.1
Materials
Aluminium extruded railing section and
baluster section shall comply with the
chemical composition and mechanical
proposals as laid down in Para 8.17.1
8.29.2
Hand Rails
There are supported on Balusters. Type of
Hand Rail shall be as specified in the item. A
few typical Hand Rail sections are given Fig.
8.18.A.
8.29.3
Baluster
Balusters are out of specified Aluminium
section. Usually it is circular/ square
aluminium rod or of designer pattern as

shown in Fig. 8.18.B.
8.29.4
Fabrication and Fixing
8.29.4.1
Baluster for specified railing
height are cut from the stipulated aluminium
section. These are properly embedded in
slab/step while its casting. Before concreting
work is started it shall be checked that
balusters is truly in position and are vertical
and top of all the balusters are in proper line.
Aluminium channels, square fillet or round
fillet as specified in the item shall be run
connecting top of all the balusters, either by
soldering, argon arc welding, wooden
screwing as may be applicable Fig. 8.18.C.
8.29.4.2
Specified
extruded
railing
section is cut for the required length. The
railing section is fixed on the top of

square/round fillet as specified in the item by
soldering, brazing etc. Precaution shall be
taken to avoid distortion of member. Gap of
any sort shall be filled with silicon sealant.
8.29.5
Measurements
Length of each member (I) Baluster (ii) Hand
rail, (iii) Channel square fillet/circular fillets
shall be measured correct
to a cm and
payment shall be worked out in running
metres correct to two places of decimals.
8.29.6
Rate
Rate includes the cost of material and labour
involved in all the operations described
above. It shall include cleats, silicon sealant
etc.
ANNEXURE 8.1
MECHANICAL PROPERTIES OF STEEL
ANNEXURE 8.2
WELDING PROCESS
(a) The work shall be positioned for
downward welding wherever possible.
(b) Arc length voltage and amperage shall
be suited to the thickness of material, type of
groove and other circumstances of the work.
The welding current and electrode sizes for
different types of joints shall be as per IS :
9595.
(c) The sequence of welding shall be such as
will avoid undue distortion and minimize
residual
shrinkage
stresses.
Recommendation of IS : 9595 shall be
followed.
Process of Welding - The electrode
manipulation during welding shall be such as
to ensure that :
(1) The parent metal is in a fused stage when
the filler metal makes contact with it.
(2) The weld metal does not overflow upon
any un-fused parent metal forming
overlapping.
(3) The parent metal is not under-cut along
the weld toes.
(4) The following metal floats, the slag, the
oxides, and the gas bubbles to the surface
behind the advancing pool. In case any of
these requirements is unattainable by
manipulation, the current shall be adjusted or
the electrode size changed.
Each time the arc is started the electrode
shall be moved in such a way that the fusion
of base metal at the starting point is assured.

At the completion of a run the movement of
electrode shall be slowed down to fill the arc
crater.
After every interruption of the arc except at
completion of a run, the arc shall be restarted
ahead of the previous deposit and then
moved back to fill the crater or such
alternative technique shall be used as will
ensure complete filling of the crater, or
complete fusion between the new and old
deposit and the base metal at the point of
junction, and result in continuity of weld.
Before welding operation is completed, all
traces of slag shall be removed from the
deposit, by chipping if necessary, and the
deposit and the adjoining base metal shall be
wire brushed and cleaned at all points. The
requirements shall apply not only to
successive layers, but also to successive
beads, and to the over lapping area where a
junction is made on starting a new electrode.
(5) The welds shall be free from cracks,
discontinuity in welding and other defects
such as (i) under-size (ii) over-size, (iii)
under-cutting and (iv) over-cutting in the case
of fillet welds and defects (ii), (iii) & (iv) in the
case of butt welds.
All defective welds which shall be considered
harmful to the structural strength shall be cut
out and re-welded. In case of welded butt
joints in steel of thickness up to 50- mm the
weld joint shall be subjected to radiographic
examination as described in IS : 1182.
All welds shall be cleaned of slag and other
deposits after completion. Till the work is
inspected and approved painting shall not be
done. The surface to be painted shall be
cleaned of spatter, rust, loose scale, oil and
dirt.
ANNEXURE 8.3
SHAPES, WEIGHTS AND DESIGNATIONS OF ROLLED STEEL SECTIONS
Designation
Wt. in
kg/m
Situation of Use of Section
T2
1.036
Horizontal-glazing bars for doors and sashes, horizontal glazing bars for
door side lights, sub-dividing bars for fixed light, vertical glazing bar for
ventilators, sash bars for window, ventilators and door where metal
aluminium or wooden beading is used for fixing glasses.
T3
1.14
Vertical glazing bar for EZ 7 frame
T6
0.839
Horizontal glazing bar for standard windows and ventilators
F2
1.46
Inner frames for open-in-windows
F3
2.28
Outer frames for open-in-windows
F5
1.55
(a) Inner and middle frames in centre-hung ventilators

(b) F5 is some times used as inner frames for open-out windows.
Also used as inner frame for bottom hung ventilators.
(c) F8 is also used as outer frame for bottom hung ventilators.
F4B
2.28
Central mullion (meeting bar for shutters) for windows using F7D as
inner frames, outer frames for open-in-windows in rainy areas,
subdividing bars for open-in-windows and top-hung ventilators.
F7D
1.419
Inner and outer frames for windows and top hung ventilators, for outer
frames for centre-hung ventilators and outer frames for door sidelights.
FX6
2.52
Inner frame for doors,
FZ7
1.90
Used as outer frame for industrial sashes. Also used for outer frame for
wooden doors.
FX8
1.92
Outer frames for doors.
FZ5
2.52
Inner frames for doors
K11B
1.80
(a) Vertical coupling mullion for standard windows.

(b) Can be used as horizontal coupling bar when open-able windows are
to be coupled above fixed ones or between two fixed windows.
(c) Can also be used as horizontal coupling mullion where windows are
not exposed to weather.
K12B
2.30
Horizontal coupling mullion, also known as weather bar, (Especially

used when the coupled unit is exposed to rain).
ANNEXURE 8.4
STEEL TUBES FOR STRUCTURAL PURPOSES
Nominal Bore
(mm)
Outside Diameter
(mm)
Class
Wall thickness
(mm)
Weight
(kg/m)
15
20
25
21.3
26.9
33.7
32
42.4
40
48.3
50
60.3
65
76.1
80
88.9
90
101.6
100
114.3
110
127.0
125
139.7
135
152.4
150
165.1
150
168.3
175
193.7
200
219.1
225
244.5
H
H
M
H
M
H
M
H
L-2
M
H
L
M
H
L
M
H
L
M
H
L
M
H
L
M
H
L
M
H
L
M
H
L
M
H
L
M
H-1
H-2
L
M
H
L
M
H
H
3.25
3.25
3.25
4.05
3.25
4.05
3.25
4.05
3.25
3.65
4.50
3.25
3.65
4.50
3.25
4.05
4.85
3.65
4.05
4.85
3.65
4.50
5.40
4.50
4.85
5.40
4.50
4.85
5.40
4.50
4.85
5.40
4.50
4.85
5.40
4.50
4.85
5.40
6.30
4.85
5.40
5.90
4.85
5.60
5.90
5.90
1.43
1.90
2.46
2.99
3.15
3.86
3.61
4.43
4.57
5.10
6.17
5.84
6.53
7.92
6.86
8.48
10.10
8.82
9.75
11.60
9.97
12.40
14.50
12.20
14.60
16.20
14.90
16.20
17.90
16.40
17.70
19.50
17.80
19.20
21.20
18.10
19.60
21.70
25.30
22.60
25.00
27.30
25.70
29.40
31.00
34.20
L means Light
M means Medium
H means Heavy
RECOMMENDED LIST OF TESTS ON MATERIALS AND WORKS

Material
Test
Field/
Laboratory Test
Text
Procedur
e
Minimum Quantity
of material for
carrying out the test
Frequency of
testing
Steel
(a) Tensile
Strength
(b) Bend
test
Laboratory
IS:1599
20 Tonne
Every 20
Tonne or part
thereof
MECHANICAL PROPERTIES OF STEEL

Annexure 8.1
Steel
Designation
Class of steel Product
ST-42-W and
ST-42-S
ST-42-O
ST-32-O
Nominal thickness/dia mm
Tensile
Strength
Kg/f/mm2
Yield
Stress
Min.
Kg/f/mm2
Percentage
Elangation
Gauge
Minimum
Length 5.65 so
Plate section
(For example,angles,
tees, beams, channels
etc.) and flats
Below 6mm only bend

test shall be required.
6 mm and upto 20 mm
Over 20 mm upto 40 mm
Over 40
42 to 54
42 to 54
42 to 54
26
24
23
23
23
23
Bars (round square and

Hexagonal )
Below 10 only bend test

shall be required
10 mm and upto 20 mm
Over 20 mm
42 to 54
42 to 54
26
24
23
23
Plate section
(For example,angles,
tees, beams, channels
etc.) and flats
Below 6mm only bend

test shall be required.
6 mm and above
42 to 54
26
23

Hexagonal )

shall be required
10 mm and above
42 to 54
26
23
Plate section
(For example,beams,
channels etc.) & flats
Below 6mm only bend

test shall be required. 10 mm
and above
32 to 44
26

Hexagonal )

shall be required
10 mm and above
32 to 44
26
'SO - Where so is cross sectional Area of test piece.

CHEMICAL COMPOSITION OF STEEL
Steel
Designation
ST-42-W
ST-42-S
ST-42-O
ST-32-O
Carbon
Max percentage
Phosphorous
Sulphur
0.23
* 0.25/0.28
-
0.06
0.06
0.07
0.07
Note : 0.25 for thickness or dia 20 mm and below,0.28 for thickness or cver 20 mm
0.06
0.06
0.07
0.07
SHAPES
32+.4 1.2
10 1R 1R
5
1R
2R
44+.8
2R
4
22+.4
2 R Max
2R
29+.4
2R
2 R Max
1R
11+.4
2 R Max
29+.4 1.2
3
2R
1R
1
2R
WEIGHT 1.30 KG/M

E Z7
3.5
1.2
29+.4
3
1.2
1
1R
1R
2 R Max
29+.4
2R
2R
2R
1R
5
5
3.5
2 R Max
10
2 R Max
2R
2R
2
29+.4
2R
3
1R 5
6 2R
2R
1R
3.5 1
1R
43+.8
5
15+.4
1R
13
21+.4
22+.4
1R
44+.8
33+.8
1R
15+.4
WEIGHT 2.52 KG/M

F X6
22+.4
2R
26+.4
1R
10
2 R Max
3.5
2 R Max
1R
3 3.5 1
27+.4
1R
3
1.2
WEIGHT 2.31 KG/M

FX8
WEIGHT 2.52 KG/M

F Z5
2 R Max
3R
2.5
3 3
6R
1R
9
2 R Max
3
2R
27+.8
3
15+1.2
2R
13
2R
2R
2R
23+.4
2R
2R
12
2R
2 R Max
3
3
50+.8
35+.8
WEIGHT 1.80 KG/M

K118
All dimensions are in mm
2 R Max
1.2
2R
2R
35+.8
WEIGHT 2.30 KG/M

K 12B
Drawings not to Scale
SHAPES
8
9.5
9.5
9.5
9.5
1R
16+.4
R
25+.4
22+.4
1R
2R
1R
1R
WEIGHT 1.038 KG/M

T2
1R
2R
32+.8
20+.4
1R
3
3
1R
2R
1R
1R
2 R Max
44+.8
2R
3 2R
2
22+.4
WEIGHT 1.46 KG/M

F2
2R
12+.4 2 3
3
1R
2 R Max
2R
WEIGHT 1.55 KG/M

F5
1R
2R
1.1
20+.4
2R
1R
2 R Max
13+.4
2R
2.5
2 R Max
3
2R
2R
2R
2R
2 R Max
25+.4
3 1 1R
2 R Max
WEIGHT 0.839 KG/M

T6
1.5
2R
1R
1R
2 R Max
19+.4
WEIGHT 1.14KG/M
T3
25+4
13+.4
1R
1R
2 R Max
22+.4
2 R Max
22+4
2R
2R
WEIGHT 2.28 KG/M

F3
2R
19+.4
1R
2 R Max
3 3
2R
1R
3 2
1R
1R
5
3 1
1R
2 R Max
2
7
3
2 R Max 20+.4
2R
WEIGHT 1.92 KG/M

F8
2 R Max
2
2R
1R
2R
46+.8
2R
14
20+.4
13+.4
1R
1R
14+.4
22+.4
1R
5
3
1R
2 R Max
2R
2R
22+.4
22+.4
1.5
20+.4
13+.4
2 R Max
1R
2R
2R
13+.4
WEIGHT 1.419 KG/M

F 7D
2R
1R
3
WEIGHT 2.28 KG/M

F 4B
WELDS AND RIVETS

FIGURE 8.1
X Y
X Y
B. BUTT WELDS
A. BEAD WELDS
TOE
WELD FACE
ORIGINAL SURFACE OF
TOE
WORK
FUSION ZONE
ROOT
FUSIO N ZONE
D. FILLET WELD
C. PLAIN BUTT JOINT
Z
CONCAVE
CONVEX
Y
X
MITRE
Z
Z = DEPTH OF FUSION
X = THROAT THICKNESS
Y = EFFECTIVE THROAT
THICKNESS
CORNER
1.5D
1.5D
Counter
Head
1.5D
F. FUSTION PENETRATION
1.5D
1.6D
Round
Sunk
LAP
E. FILLET WELDS
Flat
Sunk
Counter
Head
2.5D
Bend
Test
Pan
Head
Flattening
Test
0.70
d
D
d
SHANK TAIL
G. RIVETS
d = EFFECTIVE DIAMETRE
D = NORMAL DIAMETRE
COLLAPSIBLE STEEL GATE

FIGURE 8.2
20x10x2 CHANNEL
IRON 3.5 KG\M
T-IRON 40x40x6
TIRON
40 x 40 x6
CHANNEL
20x10x2
3.8 DIA BALL BEARING

FLAT IRON HANGER
RIVETS
FIXING WITH
HOLD FAST TO
WALL
FLAT IRON
20 x 5
LOCKING
ARRANGE
MENT
HANDLE
HEIGHT
LOOK
HOLDING
HOOK
PULLEY OR 38 MM
BALL BEARING
HANDLE
RIVETS
L
100
SECTION
PULLEY OR 38 MM
BALL BEARING
FRONT ELEVATION
450
OPENING
100
CHANNEL
FRONT ELEVATION
450
OPENING
PLAN
PLAN
FIG. 8.3 MS SHEET SLIDING SHUTTERS

FIGURE 8.3 A & B
PULLY 25 O
O
X
C
PULLY GUIDE BLOCK
ANGLE IRON
M.S. CHANNEL 40x40x6
GUSSET PLATE 3.15 THICH
WALL
40 x 40 x 6
ANGLE IRON
12 GAP MAX
M.S. SHEET 1 THICK

RIVETS
1 THICK M.S. SHEET
HANDLE
ANGLE IRON 40x40x6
M.S. CHANNEL
M.S. CHANNEL
M.S. TEE 40x40x6

PULLY OR BALL
BEARING 25 DIA.
ANCHOR BOLTS
RIVETS
Y
SECTION CD
FIG. 8.3B MS SHEET SLIDE HUNG SHUTTERS

RIVETS
PULLY 25
ANGLE IRON
40x40x6
PIN TEE FIXED WITH

BOLTS AND NUTS
WALL
30x6 M.S
FLAT OR
40x40x6
40x40x6 ANGLE
IRON OR 10x5 M.S
ANGLE IRON
DETAIL AT X
PINTLE FIXED
WITH RIVETS
(ALTERNATIVE
TYPE CLEAT)
40x40x6
ANGLE IRON
GUSSET PLATE
RIVETS
M.S. LOWER
2400
SIDE HUNG
BOLT
ANGLE IRON 40x40x6

M.S. CHANNEL
PULLY OR BALL BEARING

2.5 DIA
M.S. PLATE 1.15 THICK
DETAIL AT Y
STEEL DOORS, WINDOWS & VENTILATORS

FIGURE 8.4
FIXED
TOP HUNG BOTTOM HORIZONTAL VERTICAL

HUNG
PIVOTTED
CENTRAL HUNG
SIDE
HUNG
Head or
Frame
Mullion
Top rail
Transone
Glazing bar
57.5 cm
Glass
Pane
Mullion
117.5 cm
Lock
Rails
Meeting
Stile
Lock
Plate
207.5 cm
Handle
Hahdle
Stile
Bottom rnl
Sill
117.5 cm
Lugs
Frame
Kick plate
(1.2 mm Thick)
All corhers mitred and
welded to true right angle
Sill
117.5 cm
Note : The figure also illustrates

The important parts
COMPOSITE UNIT
16
Putty
Clip
100 mm
Putty
25
GLAZING CLIPS
3
10
3
45
70
SLOTTED LUG
FIXING OF STEEL DOORS, WINDOWS & VENTILATORS

FIGURE 8.5
Cement concrete lintel
Plug
Width of opening
Rendering
Width of Ventilator
Putty
Hold fast
Glass
Cement mortor
Height
of
Window
Brick Jamb
Cement Mortor
Height
of
Ventilator
(Masonry Openings)
Width of opening
Width of window
Putty
Glass
(Masonry Openings)
A. Flush with rendering
Timber surround
A. Flush with rendering

Fair face
Wood screw
Putty
Hold fast
3
25
Glass
Jamb
Height
of
Window
Cement mortor
Plaster
(Masonry Openings)
B. Flush without rendering

Plug
Wood
Screw
Jamb
Solid
Metal
Bead
Plug
Glass
Wood
Screw
Jamb
Putty
Plaster
10
Fixing clip
Width of opening
Width of door
Width of opening
Width of window
Pully
Glass
Wooden or
Metal bead
(Masonry Openings)
C. Rebated without rendering
B. Fixing to wood work surround

Fair face
Width of opening
Width of window
Fair face
Mastic
Putty
Glass
Plaster (Masonry Openings)

Rebated without rendering
Glass
Rolled steel angle
Hold fast
Rolled
Steel
Angle
3
Putty
D. Rebated with rendering
Mastic putty 12.5

Width of steel
Work opening
Glass
(Masonry Openings)
E. Fixing to steel work
19
M.S. Or hard
Wood block
Mastic
Putty
T - IRON - DOOR\WINDOW FRAMES

FIGURE 8.6
LINTEL
LEVEL
ISECTION FRAME
SOCKET PLATE
WELDED TO
FRAME
STANDARD
FITTING WELDED
TO FRAME
TOWER
BOLT
TOWER BOLT
PLASTERT
IRON FRAME
FLUSH DOOR
SHUTTER
TEAK PLY
PACKING
G.I. SOCKET
EMBEDED IN
FLOOR
FINISHED
FLOOR LEVEL
CLEARANCE
TOP
TOP
FIXING TOWER BOLTS TO SHUTTERS
BOTTOM
T - IRON - DOOR\WINDOW FRAMES

FIGURE 8.6
Butt welded
Mitre joint
Plaster 12/15 mm
Wall
MS T-Iron 40x40x6 mm
Steel
Screws
Shutter
90
T-Iron
Welding for'T' -Iron frames
Screw used in wood work

Welding
WELDING FOR 'T' -IRON FRAMES

SKETCH A
M.S Butt hinges

25x6 mm M.S
Flat 100 mm long
FIXING BUTT HINGES TO T-IRON FRAME WITH M.S. FLAT
WELDED TO FRAME
Fillet weld
Brick
Wall
M.S flats
Plaster 12/15mm
T-Iron frame 40x40x6 mm
Shutter
M.S. FLAT WELDED TO M.S. FLAT

SKETCH B
Screws
Welding
M.S Flat
M.S bar
M.S Butt hinges

100x58x1.9 mm welded
Directly with the frame
on three sides
ALTERNATE METHOD OF FIXING HINGES TO 'T' -IRON FRAMES
[DIRECT WELDING THE HINGES TO 'T' IRON FRAMES]
Fillet weld
M.S bar welded to M.S Flat
PRESSED STEEL DOOR & WINDOW FRAMES

FIGURE 8.7
165
105/125
12
12
12
12
60
45
15
45
15
45
PROFILE
PROFILES A&B
50x25 MIN ANGLE

THRESOLD
5 MM
5 MM
CLEARANCE
CLEARANCE
THRESOLD
FL
11 FL
FLOOR
50x25 MIN
LEVEL
ANGLE
THRESOLD
WITH THRESOLD FOR
WITH THRESOLD FOR
EXTERNAL DOOR
WITH OUT THRESOLD
EXTERNAL DOOR
OPENING INWARDS
OPENING OUTWARDS
Arrangeement at base of door frame

HEAD
40 MIN
Y
TAR
200
25
HINGE
Profile
A
B
C
Y
95
120
160
450 MM
950 TO CENTRE OF
LOCK STRIKE
BUFFERS
450 MM
LOCK STRIKE PLATE

DOOR SHUTTER
FIXING SCREW
WELDED TO FRAME
BUFFRS SHOCK
DOOR FRAME ABSORBERS
Fixing of hinge to the frame
Location of shock absorbers and

Lock strike plate
FAN CLAMPS
FIGURE 8.8
200
Top of slab
75
200
25 min
16
32
16
17
Dislribution
Remforcement
Main Reinfor cement
Tie bar
Exposed Loop shall
be painted 16 mm
200
Ceiling Finish
50
100
200
75
Top of slab
R.C.C slab
II
R.C.C Beam RIB
32
Reinforcement bar
100 min
Exposed loop
Shall be painted
50
160
Top lid 1.5th
III
Hole for conduit entery

15
36.5
76 73
36.5
Elevation
100 Coiling finish
180
585
Bottom lid
12
13
1.5th
3.3 mm dia
Tapped hole
Section
5
140
Circular cast iron box
16
PLAN WITHOUT TOP AND BOTTOM LID
EXTRUDED SECTIONS FOR DOORS

AS PER IS 1948-1961
FIGURE 8.9
(A) FIXED FRAME
SECTION NO. AL-FXB
(B) SHUTTER FRAME HOLLOW SECTION
WEIGHT :0.805 KG/M

20.6
(ii) SECTION NO. AL- HFX6

WEIGHT : 0.73 Kg/m
6.4
3.2
3.2
15.9
9.5
4.8
29.0
3.2
3.6
2
3.2
22.2
3.2
2
29.0
22.2
42.9
22.2
12.7
3.6
3.2
44.4
(B) SHUTTER FRAME HOLLOW SECTION

(i) SECTION NO.AL-HFX5
WEIGHT :0.73 Kg/m
15.9
(C) SHUTTER FRAME SOLID SECTION
3.2
(ii) SECTION NO. AL- FX6

WEIGHT : 1.033 Kg/m
3.2
22.2
28.6
29.0
3.2
3.2
3.5
22.2
12.7
29.0
8.4
44.4
3.2
(C) SHUTTER FRAME SOLID SECTION
22.2
9.5
(i) SECTION NO.AL-FX5

WEIGHT :1.033 Kg/m
44.4
19.0
9.5
(D) GLAZING BAR

SECTION NO. AL-T 6
3.2
8.4
WEIGHT : 0.363 Kg/m
29.0
3.2
19.0
3.2
22.2
44.4
3.2
25.4
ALUMINIUM DOORS
FIGURE 8.10 A to 8.10 H
Putty
Outside
Glass Pane
1175
Horizontal Section of Door
600
Ventilator
Door
2687.5
Floor
Level
Type
12 HT 6
12HS21
Ventilator
Size of opeming
= 1200x(600+2100)mm
=1200x2700 mm
Mastic
12 HT 6= Top Ventilator
width 1200 mm (opening) with
horizontal glazing bar and top
hung shutters
12 HS 21 = Door below of width
1200 mm (Opening) with horizontal
glazing bar and side
hung shutters
Glass
Height of complete unit 2700
Pane
mm (opening)
Door
50 mm
Leg 50 mm long
Size of Glass (Clearance Allowed)

NOS.
12 HT 6
SIZES
NOS.
WIDTH x HEIGHT cm
12 HS 21
SIZES
WIDTH x HEIGHT cm
Vertical Section of Door

54.5 x 24.5
2
9
1
50.5x24.0
50.5x27.5
40.5x27.5
Fig.8.10 A Fabrication of Aluminium Door
50 mm
Projecting Hinges
(Welded or
Riveted ) to allow
Door to Fold back
against the Wall
Plain Hinge
Fig -8.10 B Typical Projecting Type Hinge

for Door
Fig 8.10 C Typical Non -Projection Type

Hinge for Door
Plate
Strip'A' Riveted
to Locking strip
Tee Bars
Upper Locking
Strip
Washer
Stopper
90 mm
Lever
Lever
Slot for
Lever
70 mm
87 mm
Door Section
Guide Pin
Riveted to the
section at the
Back
Lock
24 mm
25 mm Long
slot in the
Locking strip
Bolt
100 mm
Lower locking
Strip
Tee Bars
Fig 8.10 D Typical Vertical Bolt for

Double Shutter Door
Strip 'B' riveted to

locking strip
Fig 8.10 E Typical three-Way Bolting Device for Doors
20.35
Size of Opening
1.25 cm
Overall Size of Door, Window

and Ventilator
1.25 cm
15 mm
Unfinished Wall
15 mm
Lugs
Fig 8.10F Fixing of Aluminium Doors, Windows or Ventilators in opening

in Masonry by use of Steel lugs
Fig. 8.10 G Slotted Fixing lug (For Brickwork and Masonry)

3
10
3
45
12.5
3.2
100 min
16
70
Fig. 8.10 H Fixing Clip for steel Work

40
25
8 mm O
Hole
40
20
B
Putty
Extruded
Coupling
Section
25 mm
mastic
Cement
Weather Bar
between
Ventilator and
Window
COUPLING SECTION EXTRUDED HAVING WEATHER BAR FITTED
VENTILATORS ON TOP OF WINDOW
Fig. 8.11 D Construction details at position 'B' in An Aluminium Window Coupled

with Ventilator
C
50 mm
0.90 mm
Push fit
Weather Bar
AI-F4B
AI-CE 6
WEATHER BAR OVER EXTERNAL OPENING SHUTTER
WITH FIXED LIGHT ABOVE
Fig. 8.11 E Construction details at Position 'C' in an Aluminium Window Coupled with Ventilator
22 mm
Welded
67 mm
Welded
Welded or
Riveted
Fig. 8.11 F Typical Projecting Type Hinge

for side - Hung shutter
Locking washer Grips under side

of Hinge and Prevents nut from
working loose
Fig. 8.11 G Typical Non-Projecting Type Hinge

For Side - Hung Shutter
Stainless steel Washer in pairs

back to back with serrated surfaces.
Fig. 8.11 H Illustration Showing Working Principle of Friction Hinges
ALUMINIUM WINDOWS - OPENING TYPE

FIGURE 8.11 A to 8.11 K
(a) OPENING FRAME
SECTION NO. AL - CF6
(b) GLAZING BARS

SECTION NO. AI-T7
WEIGHT :0.334 Kg/m
SECTION NO. AI-T6

WEIGHT : 0.306 Kg/m
WEIGHT: 0.614 Kg/m

20.6
2
3.2
19.0
3.2
19.0
3.2
120
25.4
4.8
12.7
3.2
3.2
3.2
19.0
22.2
33.3
(C) COUPLING MEMBER
COUPLING WITH WEATHER BAR
COUPLING
SECION NO.AI-HK 11B
WEIGHT : 1.15 Kg/m
SECTION NO. AI-HK 12B

WEIGHT :1.61 Kg/m
15.9
15.9
3.2
3.2
R
R
55.6
3.2
55.6
15.9
R
3.2
38.1
50.8
6.4

Fig. 8.11 A Extruded Section for Openable Window (As per IS Code)
MULLION WITH BOTH SIDES
Fig. 8.11 B Construction details of Location 'A' Marked in a Single Aluminium Window
X
MULLION WITH FIXED GLASS ON ONE SIDE AND SIDE- HUNG ON
OTHER SIDE
Fig. 8.11 C Construction details at section XX in a Single Aluminium Window
In Relation to
33 mm
Fixing Screw
Shake Proof
Washer
3 mm
117.5cm
Wedge Shape
Striking Plate
11 mm Round or
Square Hole
4 mm
87.5cm
10.3 mm
12 MODULE (117.5 cm)
HIGH WINDOWS
Fig. 8.11 I Typical Handle for side Hung Shutter
9 MODULE (87.5 cm)

HIGH WINDOWS
Fig. 8.11 J Showing the position of handle

Height of "HS" type windows
Plates In Relation to
H = Withhorizontal glazing bars

S = Side hung shutters
80mm
to web
73 mm
30 mm
22 mm
20 mm
75 mm
65 mm
65 mm
Locking Bracket
75 mm
300 mm
Fig. 8.11 K A Typical peg stay for side - Hung shutters and
Top-Hung Ventilators
8 mm pin
18 mm
ALUMINIUM WINDOWS - SLIDING TYPE

FIGURE 8.12
Breadim 2.5 less than the breeacm

Prescribwd drawing/Item
e
LENGTH 2.5 cm LESS THAN THE LENGTH PRESCRIBAD IN DRAWING/ITEM
Track Top & Side
Side Handle
Track Top & Side
Detail - dd
Inter Lock
Shutter Top & Bottom
Shutter Top &

Bottom
Track Top & Side
Top & Bottom

Detail -aa
Detail -bb
Detail -bb
Detail -cc
Detail -ee
Track Bottom
Fig. 8.12 Sliding Window Assembly - 3 Tracks
FIGURE 8.13A to 8.13 C
(B) OUTER BAR FOR VENTILATOR
(A) VENTILATOR BAR
SECTION NO.AI-F8
WEIGHT : 0.63 Kg/m
SECTION NO.AI-F5
WEIGHT : 0.614 Kg/m
22.2
3.2
3.2
13.5
12.7
33.3
32.5
4.8
120
4.8
3.2
19.8
3.2
3.2
25.4
25.4

Fig. 8.13 A Extruded Sections for Ventilator (As per IS Code)
DETAIL THROUGH BOTTOM OF TOP HUNG

VENTILATOR
Fig . 8.13 B Construction Details of Location 'A' Marked at bottom of TOp Hung Ventilator
Below Pivot
Above Pivot
Fig. 8.13 C Details of Horizontal Centre - Hung Ventilator
FIGURE 8.14 A to 8.14 D
(B) COUPLING
SECTION NO.AI-HK 11B
WEIGHT : 1.15 Kg/m
(A) MULLION BAR

SECTION NO.AI-F4B
WEIGHT : 0.837 Kg/m
(C) COUPLING WITH WEATHER BAR

SECTION NO.AI-HK 12 B
WEIGHT : 1.61 Kg/m
46.0
Figure shown in 8.11 A

25.4
Figure shown in 8.11 A
4.8
19.0
3.2
20.6
12.7
Fig. 8.14 A Extruded Section for Composite Units (As per IS Code )
(12 modules + 15 modules = 27 modules)
2700 mm
(1500-Y)
Ventilator
over Door
Ventilator
over window
(600.x)
Mullion
Transome
Y
Door
12.5mm
1175
(600 .x)
2087.5
(21 modules + 6 module = 27 modules)

2700 mm
12.5mm
Window
(12 module+ 6 module = 18 modules)

1800
12.5 mm
1175
X = Width of Transome
Y = Width of Mullion
12.5mm
Opening
Floor Level
(9 module)
900
12.5mm
50 mm Leg
Fig. 8.14 Dimension of the Opening and the Size of Different of

Composite Unit to Facilitate Proper Fixing in the Opening
25 mm
Putty
Fig. 8.14 C Coupling Windows side by

side making a composite window
(See Details in Fig. 8.14 D
Mastic
Fig. 8.14 D Coupling Section Extruded

for Coupling Windows side by side
FLOOR SPRING (HYDRAULICALLY OPERATED)

FIGURE 8.15
Half Cover
Roller
Box
Roller
Governing
Pivol
Spring
Spring Tension
Guard
Main Box
Cylinder
Piston
Capstan
Nuts
Control
Valve Screw
Fig. 8.15 Typical Details of Floor Spring (Hydraulically Regulated)
CURTAIN WALL SYSTEM COMPONENTS

FIGURES 8.16 A
Head
Insulating Panel
Galvanized
Steel Sash
Flashing
Support
Bracket
Expansion
Joint
Glass
Sill
Insulating Panel
Galvanized
Steel Anchor
Fig.8.16A Components of curtain wall with window panels
CURTAIN WALL FRAME

FIGURES 8.16 B
Equal division
Joint to be filled with

Silicon Sealant.
1000
Mullion
C
650
2000
2000
650
Transome
Transome
78.30x57
(8407)
Mullion
115.90 x57
(9665)
Mullion
Transome
Line
Cover plate
57x17.25
(9064)
Glass
Presure plate
56.50x10.00
(9065)
EPDM
Gasket
DETAIL AT 'B'
DETAIL AT 'A'
Transome
Finished Level
Spandrel
650
5mm thick powder coated

MS bracket 190 x 100 x 60
Glasswool
100 mm O - 75 mm
long fisher/hilt
Mullion
DETAIL AT 'C'
Fig . 8.16 B Aluminium Frame out of Aluminium Extruded Sections in

Elevation for Curtain Wall System
ALUMINIUM STAIRCASE RAILINGS AND BALUSTERS

FIGURE 8.18 A to C
1.210 Kg/m
44.45
0.688 Kg/m
3
31.60
3.18
2.35
6.35
25.40
26
6.35
50.80
41.27
Fig. 8.18 A Typical Hand Rails
4 or
WT KG/M 0.470
3R
WT KG/M 0.641
WT KG/M 0.481
10.60
16.70
15.88
9.00
15.88
12.00
15.88
Fig. 8.18 B Typical Baluster
A
D
B
SI. NO.
1
2
3
4
A
12.00
15.00
54.00
60.00
B
9.00
12.00
32.00
30.00
0.62
1.10
3.00
4.00
0.62
1.10
3.00
4.00

Fig. 8.18 C Channels - Square Fillet
WEIGHT Kg/M.
0.048
0.109
0.907
1.210
STRUCTURAL GLAZING
FIGURES 8.17
Sealant
Mullion
111.0 x 57
Transome
74.30 x 57
Fig. 8.17 Placement of Mullions and Transome and the Sealant between RCC
Surface and Transome in structural Glazing Work

1371893623330-Steel and Aluminium Works PDF

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

1371893623330-Steel and Aluminium Works PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Unified Standard Specifications For Works & Materials

Chapter 8 : Steel And Aluminium Works

Steel sections, shall be free from excessive

Page 286 : Chapter 8

Unified Standard Specifications For Works & Materials

Chapter 8 : Steel And Aluminium Works

primer i.e. Red Oxide Zinc chrome primer

Page 287 : Chapter 8

Unified Standard Specifications For Works & Materials

scaffodling, machinery, hoisting, gear,

Chapter 8 : Steel And Aluminium Works

accurately on them and holes drilled. The

Page 288 : Chapter 8

Unified Standard Specifications For Works & Materials

Chapter 8 : Steel And Aluminium Works

1) All dimensions are in millimetres

end but where for practical reasons, greater

Page 289 : Chapter 8

Unified Standard Specifications For Works & Materials

assembling shall not distort the metal or

Chapter 8 : Steel And Aluminium Works

(k) Tools and plants will not be supplied by

Page 290 : Chapter 8

Unified Standard Specifications For Works & Materials

8.3.3.1 Steel work shall be hoisted and

Chapter 8 : Steel And Aluminium Works

of concreting, anchor bolt locations shall be

Page 291 : Chapter 8

Unified Standard Specifications For Works & Materials

the trusses, shall be paid for under this item.

Chapter 8 : Steel And Aluminium Works

welding any work shall be as per IS : 814.

Page 292 : Chapter 8

Unified Standard Specifications For Works & Materials

weight of welding material shall not be added

Chapter 8 : Steel And Aluminium Works

fixing of gate shall be made good to match

Page 293 : Chapter 8

Unified Standard Specifications For Works & Materials

vertically below the extreme clamps in the

Chapter 8 : Steel And Aluminium Works

The cleat shall have a vertical leg of 150 mm

Page 294 : Chapter 8

Unified Standard Specifications For Works & Materials

8.8. ROLLING SHUTTERS

Clear width of shutters

Chapter 8 : Steel And Aluminium Works

the lath section at both ends and preventing

Depth of guide channel

Page 295 : Chapter 8

Unified Standard Specifications For Works & Materials

Chapter 8 : Steel And Aluminium Works

measured as the width of the shutter

Page 296 : Chapter 8

Unified Standard Specifications For Works & Materials

straight bars shall be bent to form a

Chapter 8 : Steel And Aluminium Works

Standard Sizes of openings

90,120 and 150*

(Note:- * Windows 150 cm in height are with fixed light above).

Page 297 : Chapter 8

Unified Standard Specifications For Works & Materials